JP2000238070A - Method for producing in-mold decorating molding sheet and in-mold decorated molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To integrate a decorative sheet with even a deep draw article so as to follow the surface of the article. SOLUTION: In an in-mold decorating molding sheet 1 constituted of at least a substrate sheet 2 and a pattern layer 3 and set to an injection mold to be integrally bonded to the surface of a molding resin, the substrate sheet 2 comprises a polyester film and, when a test piece of the decorated sheet with a width of 80 mm is fixed between a pair of chucks, which are spaced apart from each other by a distance of 100 mm, under an environmental temp. of 110 deg.C and a tensile test is executed while load is applied to one end of the test piece at a constant speed of 100 mm/min, the stress value of the decorated sheet is 0.008-0.8 kgf when a tensile elongation is 150%.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to decorating a three-dimensional resin molded product such as an input panel for a home electric appliance or an interior / exterior component for an automobile, and is particularly used for decorating a deep drawn shape. The present invention relates to a method for producing a simultaneously decorated decorative sheet and a simultaneously molded decorative molded article.

[0002]

2. Description of the Related Art Conventionally, as a method of obtaining an input panel of a home electric appliance such as a rice cooker or a washing machine, a pattern is printed on a biaxially stretched polyester film to obtain a decorative sheet. After processing into a three-dimensional shape and cutting and removing unnecessary parts, it is supplied into an injection molding die to mold a three-dimensional molded product and simultaneously attach a decorative sheet to the molded product and decorate it. There was a way to do it.

[0003]

However, the biaxially stretched polyester film has inferior elongation properties, so that when the molded article has a three-dimensional shape with a deep drawing, the decorative sheet follows the molded article surface. There was a problem that it could not be integrated.

Accordingly, the present invention solves the above-mentioned problems, and provides a simultaneously-molded decorative sheet and a simultaneously-molded decorative sheet in which even if the product is a deep-drawing molded product, the decorative sheet can be integrated following the surface of the molded product. An object of the present invention is to provide a method for manufacturing a decorative molded product.

[0005]

Means for Solving the Problems The simultaneously decorated decorative sheet of the present invention has the following constitution in order to achieve the above object.

That is, the simultaneous-decoration sheet of the present invention comprises at least a base sheet and a design layer, is set in an injection molding die, and is integrally bonded to the surface of a molding resin. In the sheet, the base sheet is made of a polyester film, and a test piece of a decorative sheet having a width of 80 mm is fixed at a distance between a pair of chucks of 100 mm at an environmental temperature of 110 ° C.
A tensile test is performed by applying a load at a constant speed of 0 mm / min, and the stress value when the tensile elongation is 150% is 0.008 to
It was configured to be 0.8 kgf.

In the above invention, the polyester film may be a copolymer film formed of a polymer of a polyhydric carboxylic acid and two or more polyhydric alcohols.

In the above invention, the polyester film may have a crystallinity of 0 to 30%.

Further, in the above invention, the simultaneously decorated decorative sheet may be an insert material.

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

Further, according to a method of manufacturing a simultaneously-decorated molded article of the present invention, the three-dimensionally processed simultaneously-decorated sheet according to any one of claims 1 to 5 is arranged in a molding die. At the same time as forming the resin molded product by closing it, a simultaneous molding decorative sheet was integrally bonded to the surface thereof.

Further, according to the method of manufacturing a simultaneously-decorated molded article of the present invention, the simultaneously-decorated simultaneously-decorated sheet according to any one of claims 1 to 5 is arranged in a molding die, and three-dimensionally processed in the die. After that, the mold was closed to form a resin molded product, and at the same time, the simultaneous molding decorative sheet was integrally adhered to the surface thereof.

[0013]

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

FIG. 1 is a cross-sectional view showing one embodiment of a simultaneously decorated decorative sheet of the present invention. 2 to 4 are cross-sectional views showing one of the steps of the method for producing a simultaneously decorated decorative molded product according to the present invention. FIG. 5 is a cross-sectional view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention. FIG. 6 is a plan view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention. FIG. 7 is a cross-sectional view showing a three-dimensionally processed simultaneously-decorated sheet used in the method for producing a simultaneously-decorated molded article of the present invention. 8 and 9 are cross-sectional views showing one of the steps of the method for manufacturing a simultaneously decorated decorative molded product according to the present invention. FIG.
FIG. 2 is a perspective view showing an apparatus for applying a load to a test piece of a simultaneously decorated decorative sheet. FIG. 11 is a plan view showing a portion for fixing a test piece of an apparatus for applying a load to the test piece of the simultaneously decorated decorative sheet. FIG. 12 is a cross-sectional view showing a portion for fixing a test piece of a device for applying a load to the test piece of the simultaneously decorated decorative sheet. In the drawing, 1 is a simultaneously decorated decorative sheet, 2 is a base sheet, 3 is a design layer, 4 is an adhesive 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 gate. Reference numeral 10 denotes a molded resin, 11 denotes a resin molded product, 12 denotes a vacuum suction hole, 13 denotes a cavity, 20 denotes a test piece, 21 denotes a screw, 22 denotes a chuck, 23 denotes a chuck, and 24 denotes a movable member.

The simultaneous decorative sheet 1 of the present invention comprises at least a base sheet 2 and a design layer 3 and is set in an injection mold and integrally adhered to the surface of a molding resin 10. In the decorative sheet 1, the base sheet 2 is made of a polyester film, and the test piece 20 of the decorative sheet having a width of 80 mm is fixed at a distance between a pair of chucks of 100 mm at an environmental temperature of 110 ° C.
Is subjected to a tensile test by applying a load at a constant speed of 100 mm / min, and has a stress value of 0.008 to 0.8 kgf when the tensile elongation is 150% (see FIG. 1).

The base sheet 2 is made of a polyester film, and a test piece 20 of a decorative sheet having a width of 80 mm at an environmental temperature of 110.degree.
mm, and a tensile test was performed by applying a load to one end of the test piece 20 at a constant speed of 100 mm / min.
A material having a stress value of 0.008 to 0.8 kgf at 50% is used. By using a substrate film having such characteristics, elongation characteristics suitable for deep drawing can be obtained.

The vacuum forming method is taken as an example of the three-dimensional processing, and the cause of the occurrence of problems when a biaxially stretched polyester film is used as the base sheet 2 was investigated. N / m ²
(= 0.1 N / mm ² ), and it was found that sufficient deep drawing should be performed at a pressure lower than this pressure. The thickness of the base sheet 2 is 0.01
If it is less than 1 mm, there is a problem in printability, and if it is more than 1 mm, it is difficult to wind it into a roll, so the range of 0.01 to 1 mm is preferable. This is a test piece 20 with a width of 80 mm.
In the case of a cross-sectional area having a thickness of 1 mm (cross-sectional area of 80 mm ² ), 8
N, ie, a pressure at which a stress of about 0.8 kgf is applied.
Further, when the thickness is 0.01 mm, 0.08 N, that is, about 0.3 mm.
This corresponds to a pressure at which a stress of 008 kgf is applied. Under a suction pressure in this range, the elongation of the biaxially stretched polyester film is about 105 to 120% even when heat is applied, and hardly elongates, and deep drawing cannot be performed. On the other hand, by selecting a polyester film having a low degree of stretching or unstretched, it is possible to obtain a polymer film in which the polymer chains are not oriented and the crystallized portion is reduced, and the polymer chains move well and have flexibility. it can.

In the present invention, deep drawing can be performed by employing a polyester film having a stress value of 0.008 to 0.8 kgf when the tensile elongation is 150%. If the stress value is lower than 0.008 kgf, when forming the pattern layer 3 or the like, the tension of the printing machine causes a large expansion in the polyester film, so the register is not registered, and it is difficult to form the pattern layer 3 as intended. It becomes difficult. On the other hand, if the stress value is larger than 0.8 kgf, the elongation does not reach 150% even when heated due to insufficient suction pressure, and sufficient deep drawing cannot be performed. Therefore, the polyester film having the above characteristics has both printability and deep drawability.

The environmental temperature is the temperature of the atmosphere in which the test piece 20 is actually tested. The reason why the environmental temperature is set to 110 ° C. is that the lowest temperature of 110 ° C. is adopted among the temperatures suitable for three-dimensionally processing the polyester film. This is because three-dimensional processing at a processing temperature as low as possible can prevent thermal deterioration of the ink of the symbol layer 3 and the metal thin film layer. At a higher temperature, the polyester film of the present invention is more easily stretched and easily processed.

The test piece 20 is cut into a size that can be subjected to a tensile test at a width of 80 mm and a distance between a pair of chucks of 100 mm. The dimensions of the test piece 20 are set to such values because the dimensions of the input panel of the rice cooker whose production was actually studied were 80 mm in length and 100 mm in width, and the values were adopted. Building materials sheets such as input panels and bars of washing machines have many shapes that are longer and narrower than this ratio. However, the result of evaluating the material selected based on the above test results of 80 mm x 100 mm was good, so the evaluation was made with this dimension. I confirmed that it was meaningful.

10 to 12, the upper pair of chucks 22 are fixed by screws 21 with the upper end of the test piece 20 sandwiched therebetween. The lower pair of chucks 23 are fixed by screws 21 with the lower end of the test piece 20 sandwiched therebetween. As shown in FIG. 10, the upper pair of chucks 22 are fixed to the test apparatus, while the lower pair of chucks 23 are attached to the movable member 24 and
The test piece 20 is lowered at a speed of 00 mm / min to apply a tensile force.

The speed at which the test piece 20 is pulled is 100
The value of mm / min adopts the lowest value of the speed at which the simultaneously decorated decorative sheet 1 is stretched during three-dimensional processing.

As the polyester film, it is preferable to use an amorphous or low-crystalline film having a crystallinity of 0 to 30%.

The crystallinity refers to the ratio of the weight of the crystalline portion to the total weight of the sample. The crystalline portion is characterized by high density and softening point, low impact resistance, and high elastic modulus. is there. Therefore, the elongation characteristics tend to decrease, and as a result of examination, it has been found that when the crystallinity exceeds 30%, it becomes difficult to perform three-dimensional processing even if the temperature is increased. Examples of the method for measuring the degree of crystallinity include measurement of density, specific heat, and heat of fusion, X-ray diffraction, infrared analysis, and nuclear magnetic resonance.

As the polyester film, it is preferable to use a polyester copolymer film formed of a polymer of a polyvalent carboxylic acid and two or more polyhydric alcohols.

If a polycondensation product of a polyhydric carboxylic acid and one kind of polyhydric alcohol such as an ordinary unstretched polyester film is used, crystallization proceeds with time, elongation characteristics are reduced, and cracks occur. . However, polyester-based copolymer films containing two or more polyhydric alcohol functional groups in the molecular chain have an irregular and asymmetric molecular arrangement, and the functional group is larger than the ethylene group. There are features that are difficult to align with each other, and these features do not change over time. Therefore, it is difficult to crystallize over time. As the two or more kinds of polyhydric alcohols, those containing ethylene glycol, propylene glycol, methylene glycol, alkylene glycol, pentyl glycol, cyclohexanedimethanol, or derivatives thereof as main components may be used.

A transfer material or an insert material can be used as the simultaneously decorated decorative sheet 1 used in the present invention.

The insert material is formed by forming a pattern layer 3 on a base sheet 2 (see FIG. 1).

The pattern layer 3 may be formed by printing a pattern on one or both of the front and back surfaces of the base sheet 2. The design layer 3 is usually formed as a printing layer. As the material of the printing layer, urethane resin, vinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, alkyd resin, heat It is preferable to use a colored ink containing a resin such as a plastic elastomer, preferably a resin capable of forming a flexible film as a binder and a pigment or dye of an appropriate color as a colorant. 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 may be used. In particular, an offset printing method or a gravure printing method is suitable for performing multicolor printing and gradation expression. In the case of a single color, a coating method such as a gravure coating method, a roll coating method, and a comma coating method can be adopted. The printing layer may be provided entirely or partially depending on the design to be expressed.

The design layer 3 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 the design layer 3, and is formed by a vacuum deposition 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. As an example of forming a partial metal thin film layer, after forming a solvent-soluble resin layer in a portion that does not require a metal thin film layer, a metal thin film is entirely formed thereon, and solvent cleaning is performed. There is a method of removing an 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, an adhesive layer 4 may be formed. The adhesive layer 4 is for bonding an insert material to the molding resin 10, and is formed on the design layer 3 side or the base sheet 2 side of the simultaneously decorated decorative sheet 1 as necessary. As the adhesive layer 4, a heat-sensitive or pressure-sensitive resin suitable for the material of the molding resin 10 is appropriately used. For example, when the material of the molding resin 10 is an acrylic resin, an acrylic resin may be used. When the material of the molding resin 10 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. Furthermore, when the material of the molding resin 10 is a 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 4 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.

Next, the case where the simultaneously decorated decorative sheet 1 is used as a transfer material will be described. The transfer material is such that a transfer layer including a release layer, a design layer 3, an adhesive layer 4, and the like is provided on a base sheet 2.

As the base sheet 2, the same sheet as that of the insert material can be used. In order to improve the releasability of the transfer layer from the base sheet 2, the base sheet 2
Before providing a transfer layer thereon, a release layer may be formed over the entire surface. When the base sheet 2 is peeled off after the transfer, the release layer is released from the transfer layer together with the base sheet 2. 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, a polyolefin resin-based release agent, Paraffin-based release agents, composite release agents thereof, and the like can be used. As a method of forming the release layer,
There are coating methods such as a roll coating method and a spray coating method, and printing methods such as a gravure printing method and a screen printing method.

The release layer is formed entirely or partially on the base sheet 2 or the release layer. The peeling layer is a layer that is peeled from the base sheet 2 or the release layer when the base sheet 2 is peeled after the transfer, and becomes the outermost surface of the transfer object. 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. As a method of forming the release layer, a coating method such as a gravure coating method, a roll coating method, a comma coating method,
There are printing methods such as a gravure printing method and a screen printing method.

The design layer 3 may be provided in the same manner as in the case of the insert material.

The adhesive layer 4 is for bonding the above layers to the surface of the molding resin 10. The adhesive layer 4 is formed on a portion to be bonded. That is, if the portion to be bonded is the entire surface, the adhesive layer 4 is entirely formed on the design layer 3. Also,
If the part to be adhered is partial, the adhesive layer 4
Is partially formed. The adhesive layer 4 may be provided in the same manner as in the case of the insert material.

Next, a method for manufacturing a simultaneously decorated decorative molded product will be described.

First, the simultaneously-molded decorative sheet 1 is set on the surface of a movable mold 5 which is a mold for injection molding by a clamp member 8 (see FIG. 2).

As a specific example of the setting method to the movable mold 5, a long simultaneous molding decorative sheet 1 is once wound around a roll shaft to form a roll-shaped roll, and the roll-shaped roll is used as a movable mold for injection molding. 5 is mounted on the upper part of the movable mold 5 so as to be movable integrally with the movable mold 5, and while unwinding the simultaneously decorated decorative sheet 1 from the roll-shaped material, the sheet is passed between the retracted movable mold 5 and the fixed mold 6 and injected. What is necessary is just to wind up the simultaneously decorated decorative sheet 1 by a roll shaft of a film winding means installed below the movable mold 5 for molding so as to be movable integrally with the movable mold 5. As another example, the sheet may be set on the surface of the movable mold 5 by a robot or manually by using a single-piece shaped simultaneous decorative sheet 1. When setting the simultaneously decorated decorative sheet 1 on the surface of the movable mold 5, after arranging the simultaneously decorated decorative sheet 1 on the surface of the movable mold 5, the position of the simultaneously decorated decorative sheet 1 with respect to the surface of the movable mold 5 is changed. It is preferable that the sheet is determined by a positioning sensor or the like, and the simultaneously decorated decorative sheet 1 is pressed against the surface of the movable mold 5 for injection molding by the clamp member 8.

Next, after the simultaneously-molded decorative sheet 1 is set on the surface of the movable mold 5 for injection molding, the simultaneously decorated decorative sheet 1 is utilized by using the vacuum suction holes 12 formed in the movable mold 5 for injection molding. By vacuum suctioning the sheet 1 along the cavity forming surface 7 of the movable mold 5, the sheet 1 is processed into a three-dimensional shape along the concave portion of the movable mold 5 for injection molding, that is, along the cavity forming surface 7 of the cavity 13 (FIG. 3). As a specific example, the molded simultaneous decorative sheet 1 set on the surface of the movable mold 5 is heated to a temperature higher than its softening point by a heating plate or the like inserted between the movable mold 5 and the fixed mold 6, and is softened. The space between the concave portion of the movable mold 5 for molding and the simultaneously decorated decorative sheet 1 is sealed, and the air is evacuated from the vacuum suction hole 12 and vacuum suction is performed.
There is a method in which the simultaneously decorated decorative sheet 1 is brought into close contact with the inner surface of the concave portion (cavity forming surface 7) of the movable mold 5 for injection molding.
When processing into a three-dimensional shape, or when pressing and fixing the simultaneously formed decorative sheet 1 with the clamp member 8, an unnecessary portion of the simultaneously formed decorative sheet 1 may be punched.

In place of the above method, the simultaneous decorative sheet 1
Before setting the mold on the surface of the movable mold 5 for injection molding, the simultaneous decorating sheet 1 is formed in a desired shape in advance by using a three-dimensional processing mold different from the movable mold 5 for injection molding and the fixed mold 6. After performing three-dimensional processing and punching into a desired shape (see FIG. 7), the three-dimensionally processed simultaneous decorative sheet 1 may be fitted into the recess of the movable mold 5 for injection molding (see FIG. 7). See FIG. 8). Here, the three-dimensional processing means changing the shape of the simultaneously decorated decorative sheet 1 from a planar state to a three-dimensional shape. The desired shape includes a shape that matches the cavity forming surface 7 of the movable mold 5 or the fixed mold 6 for injection molding. As a method of processing into a three-dimensional shape, there are a vacuum molding method, a pressure molding method, a press molding method of pressing heated rubber, a press molding method, and the like. Here, the vacuum forming method is to heat and soften the simultaneous-decoration sheet 1 above its softening point, to seal the space between the concave portion of the vacuum forming die and the simultaneous-decoration sheet 1 to form a vacuum. Suction, and the simultaneous molding decorative sheet 1 is brought into close contact with the inner surface of the concave portion of the vacuum forming die,
This is a method of molding the simultaneously decorated decorative sheet 1 into a three-dimensional shape that matches the cavity forming surface 7 of the movable mold 5 for injection molding. 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 movable mold 5 is closed with respect to the fixed mold 6, and the molded resin 10 in a molten state is injected into the cavity 13 from the gate portion 9 of the fixed mold 6, and the molded resin 10 is solidified. At the same time as the resin molded article 11 is formed in 13, the adhesive layer 4 side of the simultaneously decorated decorative sheet 1 is integrally adhered to the surface thereof (see FIGS. 4 and 9).

Thereafter, after removing the resin molded product 11 from the movable mold 5, unnecessary portions of the simultaneously decorated decorative sheet 1 adhered to the resin molded product 11 are removed (see FIGS. 5 and 6). In the case where the sheet has been previously punched into a desired shape as described above, it is not necessary to remove an unnecessary portion of the simultaneously decorated decorative sheet 1.

The movable mold 5 and the fixed mold 6 as the molds for injection molding are not particularly limited to the above-described embodiment, and the fixed mold 6 and the movable mold having the gate 9 for injecting the molding resin 10 are used. The fixed mold 6 and the movable mold 5 are closed to form one or more cavities 13 surrounded by the cavity forming surfaces 7 of the fixed mold 6 and the movable mold 5. do it. The simultaneous molding decorative sheet 1 set in the cavity 13 formed by the movable mold 5 and the fixed mold 6 for injection molding,
This will cover the cavity forming surface 7. Cavity 13
May form a hole in the resin molded product 11. The recess forming the cavity 13 may be formed in either the fixed mold 6 or the movable mold 5. Movable type 5
Alternatively, the fixed die 6 may be formed around the concave portion by simultaneously forming the decorative sheet 1.
(See FIGS. 2 to 4). The clamp member 8 may be installed on the fixed mold 6 or the movable mold 5.

The molding resin 10 is not particularly limited. For example, acrylic resin, polystyrene resin,
A polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin, or the like can be used. Further, as typical molding resin 10 used for interior parts and exterior parts of automobiles, polypropylene resin containing talc, modified polypropylene resin, and the like can be given.

Next, the mold is opened to form and decorate the sheet 1 simultaneously.
Take out the resin molded article 11 which is integrated and adhered. When the simultaneously decorated decorative sheet 1 is a transfer material, the base sheet 2 is peeled off. In this way, a simultaneously decorated decorative molded article can be obtained.

As described above, in the case of a horizontal injection molding machine, the fixed mold 6 is used in the case of a vertical injection molding machine.
The relationship between the movable mold 5 and the movable mold 5 is opposite to that of the horizontal injection molding machine.
In addition, the injection molding machine has not only two molds but also three molds.
The same can be applied to the case of a sheet type.

[0048]

Example 1 A switch display panel of an electric rice cooker was manufactured under the following conditions.

A 188 μm-thick polyester copolymer film, which is a copolymer of ethylene glycol and propylene glycol, was used as the base sheet. At an environmental temperature of 110 ° C., a test piece of a simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm, and a tensile test was performed by applying a load to one end of the test piece at a constant speed of 100 mm / min. However, when the tensile elongation was 150%, the stress value was 0.23 kgf. The crystallinity was 27%.

On the base sheet, as a design layer, a character of black (containing 10% of carbon black), a pattern of gold (containing 2% of fast yellow and 25% of aluminum powder), and a pattern of pink (brilliant) by a polyester resin screen ink. A pattern of 2% of carmine and 15% of titanium oxide) and a white (20% of titanium oxide) pressing pattern were formed.

Next, an adhesive layer was formed using a vinyl chloride resin-based screen ink to obtain an insert material.

The insert material thus obtained is preliminarily vacuum-formed and then die-pressed.
The mold was placed in a molding die, and simultaneously decorated with a transparent acrylonitrile-butadiene styrene copolymer resin as a molding resin, thereby performing a decorating process to obtain a switch display panel of an electric rice cooker.

In the molded simultaneous decorative molded product which is the switch display panel of the electric rice cooker thus obtained, the simultaneously molded decorative sheet follows the surface of the molded product without distortion.

Example 2 A woodgrain-like building material was manufactured under the following conditions.

A 100 μm thick polyester copolymer film, which is a copolymer of ethylene glycol and 1,4-cyclohexanedimethanol, was used as a base sheet. 110
A test piece of the simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm at an environmental temperature of 100 ° C., and one end of the test piece was subjected to a tensile test by applying a load at a constant speed of 100 mm / min. , Tensile elongation 150%
At that time was 0.04 kgf. The crystallinity was 10%.

On the base sheet, a release layer was formed using a cellulose acetate gravure ink, and then a black (containing 10% carbon black) conduit pattern using an acrylic resin gravure ink as a design layer, and brown (iron oxide 2). % Containing) and then an adhesive layer was formed using a urethane resin-based reverse coat ink to obtain a transfer material.

The transfer material thus obtained is placed in a molding die, vacuum-molded in the die, and simultaneously decorated with a transparent acrylonitrile butadiene styrene copolymer resin containing 55% of wood powder as a molding resin. Processing was performed to obtain wood-grained building materials.

In the simultaneously-molded decorative molded product obtained as the woodgrain-like building material thus obtained, the transfer layer of the simultaneously-molded decorative sheet follows the surface of the molded product without distortion.

Example 3 A woodgrain interior panel for an automobile was manufactured under the following conditions.

A 60 μm thick polyester copolymer film, which is a copolymer of ethylene glycol and propylene glycol, was used as the base sheet. At an environmental temperature of 110 ° C., a test piece of a simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm, and a tensile test was performed by applying a load to one end of the test piece at a constant speed of 100 mm / min. However, when the tensile elongation was 150%, the stress value was 0.009 kgf. The crystallinity was 2%.

On the base sheet, as a design layer, black (carbon black 10)
%) And a tea stalk (containing 2% iron oxide).

Next, an acrylonitrile butadiene styrene resin sheet having a thickness of 500 μm was laminated by dry lamination to form an adhesive layer, and an insert material was obtained.

The insert material thus obtained is vacuum-formed beforehand, and then die-pressed.
It was placed in a molding die, and simultaneously decorated with a heat-resistant acrylonitrile butadiene styrene resin as a molding resin to obtain a woodgrain interior panel for an automobile.

The simultaneously decorated decorative molded article, which is a woodgrain interior panel for an automobile obtained in this manner, had the simultaneously molded decorative sheet following the surface of the molded article without distortion.

Example 4 A bathroom panel was manufactured under the following conditions.

A polyester copolymer film having a thickness of 1000, which is a copolymer of ethylene glycol and propylene glycol, was used as a base sheet. At an environmental temperature of 110 ° C., a test piece of a simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm, and a tensile test was performed by applying a load to one end of the test piece at a constant speed of 100 mm / min. However, when the tensile elongation was 150%, the stress value was 0.78 kgf. The crystallinity was 28%.

On the base sheet, as a design layer, a character pattern of black (containing 10% of carbon black), a pattern of red (containing 2% of carbon black), and a pattern of blue (containing 2% of carbon black) by a polyester resin screen ink were used. And a pressing pattern of white (containing 20% of titanium oxide).

Next, a 1000 μm-thick polypropylene resin sheet was adhered by print lamination to form an adhesive layer, and an insert material was obtained.

The insert material obtained in this manner is subjected to vacuum forming in advance and then die-pressed.
The mold was placed in a mold and subjected to simultaneous decorating with a polypropylene resin as a molding resin to obtain a bathroom panel.

In the simultaneously decorated decorative molded product which is the bathroom panel obtained in this way, the simultaneously decorated decorative sheet follows the surface of the molded product without distortion.

[0071]

The present invention has the following effects since it has the above-mentioned structure.

The simultaneously decorated decorative sheet of the present invention is a simultaneously decorated decorative sheet comprising at least a base sheet and a design layer, which is set in an injection mold and integrally adhered to the surface of a molding resin. The base sheet is made of a polyester film, and a test piece of a decorative sheet having a width of 80 mm is fixed at a distance between a pair of chucks of 100 mm at an environmental temperature of 110 ° C., and one end of the test piece is loaded at a constant speed of 100 mm / min. And a tensile test is performed, and the stress value when the tensile elongation is 150% is 0.008 to 0.8 kgf.
Thus, even when deep drawing is performed, the simultaneously decorated decorative sheet can be integrated with the surface of the molded product.

Further, according to the method of manufacturing a simultaneously-decorated molded article of the present invention, the simultaneously-decorated molded article in which the simultaneously-decorated sheet follows and is integrated with the surface of the molded article even when deep drawing is performed. Can be easily obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a simultaneously decorated decorative sheet of the present invention.

FIG. 2 is a cross-sectional view showing one of the steps of the method of manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 3 is a cross-sectional view showing one of the steps of the method for producing a simultaneously decorated decorative molded article according to the present invention.

FIG. 4 is a cross-sectional view showing one of the steps of the method for producing a simultaneously decorated decorative molded article according to the present invention.

FIG. 5 is a cross-sectional view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention.

FIG. 6 is a plan view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention.

FIG. 7 is a cross-sectional view showing a three-dimensionally processed simultaneously-decorated sheet used in the method for producing a simultaneously-decorated molded article of the present invention.

FIG. 8 is a cross-sectional view showing one of the steps of the method of manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 9 is a cross-sectional view showing one of the steps of the method for producing a simultaneously decorated decorative molded product according to the present invention.

FIG. 10 is a perspective view showing an apparatus for applying a load to a test piece of a simultaneously decorated decorative sheet.

FIG. 11 is a plan view showing a portion for fixing a test piece of a device for applying a load to the test piece of the simultaneously decorated decorative sheet.

FIG. 12 is a cross-sectional view showing a portion for fixing a test piece of an apparatus for applying a load to the test piece of the simultaneously decorated decorative sheet.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 Simultaneous decorative sheet 2 Base sheet 3 Design layer 4 Adhesive layer 5 Movable mold 6 Fixed mold 7 Cavity forming surface 8 Clamp member 9 Gate section 10 Molded resin 11 Resin molded article 12 Vacuum suction hole 13 Cavity 20 Test piece 21 Screw 22 Chuck 23 Chuck 24 Movable member

[Procedure amendment]

[Submission Date] May 11, 2000 (2000.5.1)
1)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Full text

[Correction method] Change

[Correction contents]

[Document Name] Statement

[Title of the Invention] Method for producing simultaneously molded decorative sheet and molded simultaneously decorative molded article

[Claims]

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to decorating a three-dimensional resin molded product such as an input panel for a home electric appliance or an interior / exterior component for an automobile, and is particularly used for decorating a deep drawn shape. The present invention relates to a method for producing a simultaneously decorated decorative sheet and a simultaneously molded decorative molded article.

[0002]

2. Description of the Related Art Conventionally, as a method of obtaining an input panel of a home electric appliance such as a rice cooker or a washing machine, a pattern is printed on a biaxially stretched polyester film to obtain a decorative sheet. After processing into a three-dimensional shape and cutting and removing unnecessary parts, it is supplied into an injection molding die to mold a three-dimensional molded product and simultaneously attach a decorative sheet to the molded product and decorate it. There was a way to do it.

[0003]

However, the biaxially stretched polyester film has inferior elongation properties, so that when the molded article has a three-dimensional shape with a deep drawing, the decorative sheet follows the molded article surface. There was a problem that it could not be integrated.

Accordingly, the present invention solves the above-mentioned problems, and provides a simultaneously-molded decorative sheet and a simultaneously-molded decorative sheet in which even if the product is a deep-drawing molded product, the decorative sheet can be integrated following the surface of the molded product. An object of the present invention is to provide a method for manufacturing a decorative molded product.

[0005]

Means for Solving the Problems The simultaneously decorated decorative sheet of the present invention has the following constitution in order to achieve the above object.

That is, the simultaneous-decoration sheet of the present invention comprises at least a base sheet and a design layer, is set in an injection molding die, and is integrally bonded to the surface of a molding resin. In the sheet, the base sheet is made of a polyester film, and a test piece of a decorative sheet having a thickness of 0.01 to 1 mm and a width of 80 mm is fixed at an environment temperature of 110 ° C. at a distance between a pair of chucks of 100 mm. A tensile test was performed by applying a load to one end at a constant speed of 100 mm / min, and the stress value when the tensile elongation was 150% was configured to be 0.008 to 0.8 kgf.

In the above invention, the polyester film may be a copolymer film formed of a polymer of a polyhydric carboxylic acid and two or more polyhydric alcohols.

In the above invention, the polyester film may have a crystallinity of 0 to 30%.

Further, in the above invention, the simultaneously decorated decorative sheet may be an insert material.

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

Further, according to a method of manufacturing a simultaneously-decorated molded article of the present invention, the three-dimensionally processed simultaneously-decorated sheet according to any one of claims 1 to 5 is arranged in a molding die. At the same time as forming the resin molded product by closing it, a simultaneous molding decorative sheet was integrally bonded to the surface thereof.

Further, according to the method of manufacturing a simultaneously-decorated molded article of the present invention, the simultaneously-decorated simultaneously-decorated sheet according to any one of claims 1 to 5 is arranged in a molding die, and three-dimensionally processed in the die. After that, the mold was closed to form a resin molded product, and at the same time, the simultaneous molding decorative sheet was integrally adhered to the surface thereof.

[0013]

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

FIG. 1 is a cross-sectional view showing one embodiment of a simultaneously decorated decorative sheet of the present invention. 2 to 4 are cross-sectional views showing one of the steps of the method for producing a simultaneously decorated decorative molded product according to the present invention. FIG. 5 is a cross-sectional view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention. FIG. 6 is a plan view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention. FIG. 7 is a cross-sectional view showing a three-dimensionally processed simultaneously-decorated sheet used in the method for producing a simultaneously-decorated molded article of the present invention. 8 and 9 are cross-sectional views showing one of the steps of the method for manufacturing a simultaneously decorated decorative molded product according to the present invention. FIG.
FIG. 2 is a perspective view showing an apparatus for applying a load to a test piece of a simultaneously decorated decorative sheet. FIG. 11 is a plan view showing a portion for fixing a test piece of an apparatus for applying a load to the test piece of the simultaneously decorated decorative sheet. FIG. 12 is a cross-sectional view showing a portion for fixing a test piece of a device for applying a load to the test piece of the simultaneously decorated decorative sheet. In the drawing, 1 is a simultaneously decorated decorative sheet, 2 is a base sheet, 3 is a design layer, 4 is an adhesive 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 gate. Reference numeral 10 denotes a molded resin, 11 denotes a resin molded product, 12 denotes a vacuum suction hole, 13 denotes a cavity, 20 denotes a test piece, 21 denotes a screw, 22 denotes a chuck, 23 denotes a chuck, and 24 denotes a movable member.

The simultaneous decorative sheet 1 of the present invention comprises at least a base sheet 2 and a design layer 3 and is set in an injection mold and integrally adhered to the surface of a molding resin 10. In the decorative sheet 1, the base sheet 2 is made of a polyester-based film, and a test piece 20 of the decorative sheet having a thickness of 0.01 to 1 mm and a width of 80 mm at an environmental temperature of 110 ° C. is a distance between a pair of chucks of 100 m.
m, and one end of the test piece 20 was subjected to a tensile test by applying a load at a constant speed of 100 mm / min.
The stress value at 0% is 0.008 to 0.8 kgf (see FIG. 1).

The base sheet 2 is a polyester film having a thickness of 0.01 at an environmental temperature of 110 ° C.
A test piece 20 of a decorative sheet having a width of 1 mm and a width of 80 mm is fixed at a distance between a pair of chucks of 100 mm, a load is applied to one end of the test piece 20 at a constant speed of 100 mm / min, and a tensile test is performed. Is 150% when the stress value is 0.0%.
What is 08-0.8 kgf is used. By using a substrate film having such characteristics, elongation characteristics suitable for deep drawing can be obtained.

The vacuum forming method is taken as an example of the three-dimensional processing, and the cause of the occurrence of problems when a biaxially stretched polyester film is used as the base sheet 2 was investigated. N / m ²
(= 0.1 N / mm ² ), and it was found that sufficient deep drawing should be performed at a pressure lower than this pressure. The thickness of the base sheet 2 is 0.01
If it is less than 1 mm, there is a problem in printability, and if it exceeds 1 mm, it is difficult to wind it into a roll. This corresponds to a pressure of 8 N, that is, a stress of about 0.8 kgf when the test piece 20 has a width of 80 mm and a cross-sectional area of 1 mm (cross-sectional area of 80 mm ² ). When the thickness is 0.01 mm, 0.08 N, that is, about 0.00
This corresponds to a pressure at which a stress of 8 kgf is applied. Under a suction pressure in this range, the elongation of the biaxially stretched polyester film is about 105 to 120% even when heat is applied, and hardly elongates, and deep drawing cannot be performed. On the other hand, by selecting a polyester film having a low degree of stretching or unstretched, it is possible to obtain a polymer film in which the polymer chains are not oriented and the crystallized portion is reduced, and the polymer chains move well and have flexibility. it can.

In the present invention, deep drawing can be performed by employing a polyester film having a stress value of 0.008 to 0.8 kgf when the tensile elongation is 150%. If the stress value is lower than 0.008 kgf, when forming the pattern layer 3 or the like, the tension of the printing machine causes a large expansion in the polyester film, so the register is not registered, and it is difficult to form the pattern layer 3 as intended. It becomes difficult. On the other hand, if the stress value is larger than 0.8 kgf, the elongation does not reach 150% even when heated due to insufficient suction pressure, and sufficient deep drawing cannot be performed. Therefore, the polyester film having the above characteristics has both printability and deep drawability.

The environmental temperature is the temperature of the atmosphere in which the test piece 20 is actually tested. The reason why the environmental temperature is set to 110 ° C. is that the lowest temperature of 110 ° C. is adopted among the temperatures suitable for three-dimensionally processing the polyester film. This is because three-dimensional processing at a processing temperature as low as possible can prevent thermal deterioration of the ink of the symbol layer 3 and the metal thin film layer. At a higher temperature, the polyester film of the present invention is more easily stretched and easily processed.

The test piece 20 is cut into a size that can be subjected to a tensile test at a width of 80 mm and a distance between a pair of chucks of 100 mm. The dimensions of the test piece 20 are set to such values because the dimensions of the input panel of the rice cooker whose production was actually studied were 80 mm in length and 100 mm in width, and the values were adopted. Building materials sheets such as input panels and bars of washing machines have many shapes that are longer and narrower than this ratio. However, the result of evaluating the material selected based on the above test results of 80 mm x 100 mm was good, so the evaluation was made with this dimension. I confirmed that it was meaningful.

10 to 12, the upper pair of chucks 22 are fixed by screws 21 with the upper end of the test piece 20 sandwiched therebetween. The lower pair of chucks 23 are fixed by screws 21 with the lower end of the test piece 20 sandwiched therebetween. As shown in FIG. 10, the upper pair of chucks 22 are fixed to the test apparatus, while the lower pair of chucks 23 are attached to the movable member 24 and
The test piece 20 is lowered at a speed of 00 mm / min to apply a tensile force.

The speed at which the test piece 20 is pulled is 100
The value of mm / min adopts the lowest value of the speed at which the simultaneously decorated decorative sheet 1 is stretched during three-dimensional processing.

As the polyester film, it is preferable to use an amorphous or low-crystalline film having a crystallinity of 0 to 30%.

The crystallinity refers to the ratio of the weight of the crystalline portion to the total weight of the sample. The crystalline portion is characterized by high density and softening point, low impact resistance, and high elastic modulus. is there. Therefore, the elongation characteristics tend to decrease, and as a result of examination, it has been found that when the crystallinity exceeds 30%, it becomes difficult to perform three-dimensional processing even if the temperature is increased. Examples of the method for measuring the degree of crystallinity include measurement of density, specific heat, and heat of fusion, X-ray diffraction, infrared analysis, and nuclear magnetic resonance.

As the polyester film, it is preferable to use a polyester copolymer film formed of a polymer of a polyvalent carboxylic acid and two or more polyhydric alcohols.

If a polycondensation product of a polyhydric carboxylic acid and one kind of polyhydric alcohol such as an ordinary unstretched polyester film is used, crystallization proceeds with time, elongation characteristics are reduced, and cracks occur. . However, polyester-based copolymer films containing two or more polyhydric alcohol functional groups in the molecular chain have an irregular and asymmetric molecular arrangement, and the functional group is larger than the ethylene group. There are features that are difficult to align with each other, and these features do not change over time. Therefore, it is difficult to crystallize over time. As the two or more kinds of polyhydric alcohols, those containing ethylene glycol, propylene glycol, methylene glycol, alkylene glycol, pentyl glycol, cyclohexanedimethanol, or derivatives thereof as main components may be used.

A transfer material or an insert material can be used as the simultaneously decorated decorative sheet 1 used in the present invention.

The insert material is formed by forming a pattern layer 3 on a base sheet 2 (see FIG. 1).

The pattern layer 3 may be formed by printing a pattern on one or both of the front and back surfaces of the base sheet 2. The design layer 3 is usually formed as a printing layer. As the material of the printing layer, urethane resin, vinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, alkyd resin, heat It is preferable to use a colored ink containing a resin such as a plastic elastomer, preferably a resin capable of forming a flexible film as a binder and a pigment or dye of an appropriate color as a colorant. 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 may be used. In particular, an offset printing method or a gravure printing method is suitable for performing multicolor printing and gradation expression. In the case of a single color, a coating method such as a gravure coating method, a roll coating method, and a comma coating method can be adopted. The printing layer may be provided entirely or partially depending on the design to be expressed.

The design layer 3 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 the design layer 3, and is formed by a vacuum deposition 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. As an example of forming a partial metal thin film layer, after forming a solvent-soluble resin layer in a portion that does not require a metal thin film layer, a metal thin film is entirely formed thereon, and solvent cleaning is performed. There is a method of removing an 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, an adhesive layer 4 may be formed. The adhesive layer 4 is for bonding an insert material to the molding resin 10, and is formed on the design layer 3 side or the base sheet 2 side of the simultaneously formed decorative sheet 1 as necessary. As the adhesive layer 4, a heat-sensitive or pressure-sensitive resin suitable for the material of the molding resin 10 is appropriately used. For example, when the material of the molding resin 10 is an acrylic resin, an acrylic resin may be used. When the material of the molding resin 10 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. Furthermore, when the material of the molding resin 10 is a 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 4 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.

Next, the case where the simultaneously decorated decorative sheet 1 is used as a transfer material will be described. The transfer material is such that a transfer layer including a release layer, a design layer 3, an adhesive layer 4, and the like is provided on a base sheet 2.

As the base sheet 2, the same sheet as that of the insert material can be used. In order to improve the releasability of the transfer layer from the base sheet 2, the base sheet 2
Before providing a transfer layer thereon, a release layer may be formed over the entire surface. When the base sheet 2 is peeled off after the transfer, the release layer is released from the transfer layer together with the base sheet 2. 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, a polyolefin resin-based release agent, Paraffin-based release agents, composite release agents thereof, and the like can be used. As a method of forming the release layer,
There are coating methods such as a roll coating method and a spray coating method, and printing methods such as a gravure printing method and a screen printing method.

The release layer is formed entirely or partially on the base sheet 2 or the release layer. The peeling layer is a layer that is peeled from the base sheet 2 or the release layer when the base sheet 2 is peeled after the transfer, and becomes the outermost surface of the transfer object. 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. As a method of forming the release layer, a coating method such as a gravure coating method, a roll coating method, a comma coating method,
There are printing methods such as a gravure printing method and a screen printing method.

The design layer 3 may be provided in the same manner as in the case of the insert material.

The adhesive layer 4 is for bonding the above layers to the surface of the molding resin 10. The adhesive layer 4 is formed on a portion to be bonded. That is, if the portion to be bonded is the entire surface, the adhesive layer 4 is entirely formed on the design layer 3. Also,
If the part to be adhered is partial, the adhesive layer 4
Is partially formed. The adhesive layer 4 may be provided in the same manner as in the case of the insert material.

Next, a method for manufacturing a simultaneously decorated decorative molded product will be described.

First, the simultaneously-molded decorative sheet 1 is set on the surface of a movable mold 5 which is a mold for injection molding by a clamp member 8 (see FIG. 2).

As a specific example of the setting method to the movable mold 5, a long simultaneous molding decorative sheet 1 is once wound around a roll shaft to form a roll-shaped roll, and the roll-shaped roll is used as a movable mold for injection molding. 5 is mounted on the upper part of the movable mold 5 so as to be movable integrally with the movable mold 5, and while unwinding the simultaneously decorated decorative sheet 1 from the roll-shaped material, the sheet is passed between the retracted movable mold 5 and the fixed mold 6 and injected. What is necessary is just to wind up the simultaneously decorated decorative sheet 1 by a roll shaft of a film winding means installed below the movable mold 5 for molding so as to be movable integrally with the movable mold 5. As another example, the sheet may be set on the surface of the movable mold 5 by a robot or manually by using a single-piece shaped simultaneous decorative sheet 1. When setting the simultaneously decorated decorative sheet 1 on the surface of the movable mold 5, after arranging the simultaneously decorated decorative sheet 1 on the surface of the movable mold 5, the position of the simultaneously decorated decorative sheet 1 with respect to the surface of the movable mold 5 is changed. It is preferable that the sheet is determined by a positioning sensor or the like, and the simultaneously decorated decorative sheet 1 is pressed against the surface of the movable mold 5 for injection molding by the clamp member 8.

Next, after the simultaneously-molded decorative sheet 1 is set on the surface of the movable mold 5 for injection molding, the simultaneously decorated decorative sheet 1 is utilized by using the vacuum suction holes 12 formed in the movable mold 5 for injection molding. By vacuum suctioning the sheet 1 along the cavity forming surface 7 of the movable mold 5, the sheet 1 is processed into a three-dimensional shape along the concave portion of the movable mold 5 for injection molding, that is, along the cavity forming surface 7 of the cavity 13 (FIG. 3). As a specific example, the molded simultaneous decorative sheet 1 set on the surface of the movable mold 5 is heated to a temperature higher than its softening point by a heating plate or the like inserted between the movable mold 5 and the fixed mold 6, and is softened. The space between the concave portion of the movable mold 5 for molding and the simultaneously decorated decorative sheet 1 is sealed, and the air is evacuated from the vacuum suction hole 12 and vacuum suction is performed.
There is a method in which the simultaneously decorated decorative sheet 1 is brought into close contact with the inner surface of the concave portion (cavity forming surface 7) of the movable mold 5 for injection molding.
When processing into a three-dimensional shape, or when pressing and fixing the simultaneously formed decorative sheet 1 with the clamp member 8, an unnecessary portion of the simultaneously formed decorative sheet 1 may be punched.

In place of the above method, the simultaneous decorative sheet 1
Before setting the mold on the surface of the movable mold 5 for injection molding, the simultaneous decorating sheet 1 is formed in a desired shape in advance by using a three-dimensional processing mold different from the movable mold 5 for injection molding and the fixed mold 6. After performing three-dimensional processing and punching into a desired shape (see FIG. 7), the three-dimensionally processed simultaneous decorative sheet 1 may be fitted into the recess of the movable mold 5 for injection molding (see FIG. 7). See FIG. 8). Here, the three-dimensional processing means changing the shape of the simultaneously decorated decorative sheet 1 from a planar state to a three-dimensional shape. The desired shape includes a shape that matches the cavity forming surface 7 of the movable mold 5 or the fixed mold 6 for injection molding. Examples of a method of processing into a three-dimensional shape 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 is to heat and soften the simultaneous-decoration sheet 1 above its softening point, to seal the space between the concave portion of the vacuum forming die and the simultaneous-decoration sheet 1 to form a vacuum. Suction, and the simultaneous molding decorative sheet 1 is brought into close contact with the inner surface of the concave portion of the vacuum forming die,
This is a method of molding the simultaneously decorated decorative sheet 1 into a three-dimensional shape that matches the cavity forming surface 7 of the movable mold 5 for injection molding. 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 movable mold 5 is closed with respect to the fixed mold 6, and the molded resin 10 in a molten state is injected into the cavity 13 from the gate portion 9 of the fixed mold 6, and the molded resin 10 is solidified. At the same time as the resin molded article 11 is formed in 13, the adhesive layer 4 side of the simultaneously decorated decorative sheet 1 is integrally adhered to the surface thereof (see FIGS. 4 and 9).

Thereafter, after removing the resin molded product 11 from the movable mold 5, unnecessary portions of the simultaneously decorated decorative sheet 1 adhered to the resin molded product 11 are removed (see FIGS. 5 and 6). In the case where the sheet has been previously punched into a desired shape as described above, it is not necessary to remove an unnecessary portion of the simultaneously decorated decorative sheet 1.

The movable mold 5 and the fixed mold 6 as the molds for injection molding are not particularly limited to the above-described embodiment, and the fixed mold 6 and the movable mold having the gate 9 for injecting the molding resin 10 are used. The fixed mold 6 and the movable mold 5 are closed to form one or more cavities 13 surrounded by the cavity forming surfaces 7 of the fixed mold 6 and the movable mold 5. do it. The simultaneous molding decorative sheet 1 set in the cavity 13 formed by the movable mold 5 and the fixed mold 6 for injection molding,
This will cover the cavity forming surface 7. Cavity 13
May form a hole in the resin molded product 11. The recess forming the cavity 13 may be formed in either the fixed mold 6 or the movable mold 5. Movable type 5
Alternatively, the fixed die 6 may be formed around the concave portion by simultaneously forming the decorative sheet 1.
(See FIGS. 2 to 4). The clamp member 8 may be installed on the fixed mold 6 or the movable mold 5.

The molding resin 10 is not particularly limited. For example, acrylic resin, polystyrene resin,
A polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin, or the like can be used. Further, as typical molding resin 10 used for interior parts and exterior parts of automobiles, polypropylene resin containing talc, modified polypropylene resin, and the like can be given.

Next, the mold is opened to form and decorate the sheet 1 simultaneously.
Take out the resin molded article 11 which is integrated and adhered. When the simultaneously decorated decorative sheet 1 is a transfer material, the base sheet 2 is peeled off. In this way, a simultaneously decorated decorative molded article can be obtained.

As described above, in the case of a horizontal injection molding machine, the fixed mold 6 is used in the case of a vertical injection molding machine.
The relationship between the movable mold 5 and the movable mold 5 is opposite to that of the horizontal injection molding machine.
In addition, the injection molding machine has not only two molds but also three molds.
The same can be applied to the case of a sheet type.

[0048]

Example 1 A switch display panel of an electric rice cooker was manufactured under the following conditions.

A 188 μm-thick polyester copolymer film, which is a copolymer of ethylene glycol and propylene glycol, was used as the base sheet. At an environmental temperature of 110 ° C., a test piece of a simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm, and a tensile test was performed by applying a load to one end of the test piece at a constant speed of 100 mm / min. However, when the tensile elongation was 150%, the stress value was 0.23 kgf. The crystallinity was 27%.

On the base sheet, as a design layer, a character of black (containing 10% of carbon black), a pattern of gold (containing 2% of fast yellow and 25% of aluminum powder), and a pattern of pink (brilliant) by a polyester resin screen ink. A pattern of 2% of carmine and 15% of titanium oxide) and a white (20% of titanium oxide) pressing pattern were formed.

Next, an adhesive layer was formed using a vinyl chloride resin-based screen ink to obtain an insert material.

The insert material thus obtained is preliminarily vacuum-formed and then die-pressed.
The mold was placed in a molding die, and simultaneously decorated with a transparent acrylonitrile-butadiene styrene copolymer resin as a molding resin, thereby performing a decorating process to obtain a switch display panel of an electric rice cooker.

In the molded simultaneous decorative molded product which is the switch display panel of the electric rice cooker thus obtained, the simultaneously molded decorative sheet follows the surface of the molded product without distortion.

Example 2 A woodgrain-like building material was manufactured under the following conditions.

A 100 μm thick polyester copolymer film, which is a copolymer of ethylene glycol and 1,4-cyclohexanedimethanol, was used as a base sheet. 110
A test piece of the simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm at an environmental temperature of 100 ° C., and one end of the test piece was subjected to a tensile test by applying a load at a constant speed of 100 mm / min. , Tensile elongation 150%
At that time was 0.04 kgf. The crystallinity was 10%.

On the base sheet, a release layer was formed using a cellulose acetate gravure ink, and then a black (containing 10% carbon black) conduit pattern using an acrylic resin gravure ink as a design layer, and brown (iron oxide 2). % Containing) and then an adhesive layer was formed using a urethane resin-based reverse coat ink to obtain a transfer material.

The transfer material thus obtained is placed in a molding die, vacuum-molded in the die, and simultaneously decorated with a transparent acrylonitrile butadiene styrene copolymer resin containing 55% of wood powder as a molding resin. Processing was performed to obtain wood-grained building materials.

In the simultaneously-molded decorative molded product obtained as the woodgrain-like building material thus obtained, the transfer layer of the simultaneously-molded decorative sheet follows the surface of the molded product without distortion.

Example 3 A woodgrain interior panel for an automobile was manufactured under the following conditions.

A 60 μm thick polyester copolymer film, which is a copolymer of ethylene glycol and propylene glycol, was used as the base sheet. At an environmental temperature of 110 ° C., a test piece of a simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm, and a tensile test was performed by applying a load to one end of the test piece at a constant speed of 100 mm / min. However, when the tensile elongation was 150%, the stress value was 0.009 kgf. The crystallinity was 2%.

On the base sheet, as a design layer, black (carbon black 10)
%) And a tea stalk (containing 2% iron oxide).

Next, an acrylonitrile butadiene styrene resin sheet having a thickness of 500 μm was laminated by dry lamination to form an adhesive layer, and an insert material was obtained.

The insert material thus obtained is vacuum-formed beforehand, and then die-pressed.
It was placed in a molding die, and simultaneously decorated with a heat-resistant acrylonitrile butadiene styrene resin as a molding resin to obtain a woodgrain interior panel for an automobile.

The simultaneously decorated decorative molded article, which is a woodgrain interior panel for an automobile obtained in this manner, had the simultaneously molded decorative sheet following the surface of the molded article without distortion.

Example 4 A bathroom panel was manufactured under the following conditions.

A polyester copolymer film having a thickness of 1000, which is a copolymer of ethylene glycol and propylene glycol, was used as a base sheet. At an environmental temperature of 110 ° C., a test piece of a simultaneously decorated decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm, and a tensile test was performed by applying a load to one end of the test piece at a constant speed of 100 mm / min. However, when the tensile elongation was 150%, the stress value was 0.78 kgf. The crystallinity was 28%.

On the base sheet, as a design layer, a character pattern of black (containing 10% of carbon black), a pattern of red (containing 2% of carbon black), and a pattern of blue (containing 2% of carbon black) by a polyester resin screen ink were used. And a pressing pattern of white (containing 20% of titanium oxide).

Next, a 1000 μm-thick polypropylene resin sheet was adhered by print lamination to form an adhesive layer, and an insert material was obtained.

The insert material obtained in this manner is subjected to vacuum forming in advance and then die-pressed.
The mold was placed in a mold and subjected to simultaneous decorating with a polypropylene resin as a molding resin to obtain a bathroom panel.

In the simultaneously decorated decorative molded product which is the bathroom panel obtained in this way, the simultaneously decorated decorative sheet follows the surface of the molded product without distortion.

[0071]

The present invention has the following effects since it has the above-mentioned structure.

The simultaneously decorated decorative sheet of the present invention is a simultaneously decorated decorative sheet comprising at least a base sheet and a design layer, which is set in an injection mold and integrally adhered to the surface of a molding resin. The base sheet is made of a polyester film, and a test piece of a decorative sheet having a thickness of 0.01 to 1 mm and a width of 80 mm is fixed at an environment temperature of 110 ° C. at a distance between a pair of chucks of 100 mm, and one end of the test piece is fixed. Since a tensile test was performed by applying a load at a constant speed of 100 mm / min and the stress value when the tensile elongation was 150% was configured to be 0.008 to 0.8 kgf,
Even when deep drawing is performed, the simultaneously decorated decorative sheet can be integrated with the surface of the molded article.

Further, according to the method of manufacturing a simultaneously-decorated molded article of the present invention, the simultaneously-decorated molded article in which the simultaneously-decorated sheet follows and is integrated with the surface of the molded article even when deep drawing is performed. Can be easily obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a simultaneously decorated decorative sheet of the present invention.

FIG. 2 is a cross-sectional view showing one of the steps of the method of manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 3 is a cross-sectional view showing one of the steps of the method for producing a simultaneously decorated decorative molded article according to the present invention.

FIG. 4 is a cross-sectional view showing one of the steps of the method for producing a simultaneously decorated decorative molded article according to the present invention.

FIG. 5 is a cross-sectional view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention.

FIG. 6 is a plan view showing a simultaneously-decorated molded article obtained by the method for producing a simultaneously-decorated molded article of the present invention.

FIG. 7 is a cross-sectional view showing a three-dimensionally processed simultaneously-decorated sheet used in the method for producing a simultaneously-decorated molded article of the present invention.

FIG. 8 is a cross-sectional view showing one of the steps of the method of manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 9 is a cross-sectional view showing one of the steps of the method for producing a simultaneously decorated decorative molded product according to the present invention.

FIG. 10 is a perspective view showing an apparatus for applying a load to a test piece of a simultaneously decorated decorative sheet.

FIG. 11 is a plan view showing a portion for fixing a test piece of a device for applying a load to the test piece of the simultaneously decorated decorative sheet.

FIG. 12 is a cross-sectional view showing a portion for fixing a test piece of an apparatus for applying a load to the test piece of the simultaneously decorated decorative sheet.

[Description of Signs] 1 Simultaneous molding decorative sheet 2 Base sheet 3 Symbol layer 4 Adhesive layer 5 Movable mold 6 Fixed mold 7 Cavity forming surface 8 Clamp member 9 Gate section 10 Molded resin 11 Resin molded article 12 Vacuum suction hole 13 Cavity 20 Test piece 21 Screw 22 Chuck 23 Chuck 24 Movable member

Claims (7)

[Claims] 1. A simultaneously decorated decorative sheet comprising at least a base sheet and a design layer, which is set in an injection mold and integrally adhered to the surface of a molding resin, wherein the base sheet is made of a polyester-based film. And 110 ° C
A test piece of a decorative sheet having a width of 80 mm was fixed at a distance between a pair of chucks of 100 mm at an environmental temperature of 100 mm, a load was applied to one end of the test piece at a constant speed of 100 mm / min, and a tensile test was performed. Is 150%, the stress value is 0.
008-0.8 kgf simultaneously molded decorative sheet. 2. The molded simultaneous decorative sheet according to claim 1, wherein the polyester film is a copolymer film formed of a polymer of a polycarboxylic acid and two or more polyhydric alcohols. 3. The crystallinity of the polyester film is 0.
The molded simultaneous decorative sheet according to any one of claims 1 to 2, wherein the content is from 30% to 30%. 4. The method for producing a simultaneously decorated decorative molded product according to claim 1, wherein the simultaneously decorated decorative sheet is an insert material. 5. The method for producing a simultaneously decorated decorative molded product according to claim 1, wherein the simultaneously decorated decorative sheet is a transfer material. 6. A three-dimensionally processed simultaneously decorated decorative sheet according to any one of claims 1 to 5, which is arranged in a molding die.
A method for manufacturing a simultaneously molded decorative article, in which a molded simultaneous decorative sheet is integrally adhered to the surface of the resin molded article at the same time as the mold is closed to form the resin molded article. 7. A resin molded product is formed by arranging the simultaneously decorated decorative sheet according to claim 1 in a molding die, performing three-dimensional processing in the die, and closing the die. At the same time, a method for manufacturing a simultaneously-decorated molded article in which a simultaneously-decorated decorative sheet is integrally bonded to the surface.