JP2001030286A - Insert molding and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain excellent appearance and decorating effect by incorporating a design layer at a base material side of a film body layer in a film with a design in the case of forming an insert molding by laminating the material and the film arranged on a surface of the material, and providing a plurality of such films with the designs. SOLUTION: In the case of manufacturing the insert molding executed by decorating, first one film 3 with a design is disposed in a mold for injection molding having a movable mold A and a fixed mold B, and the film 3 is brought into close contact with a recess of the mold A. After the mold is closed, a molten resin 2 is injected in the mold, solidified, then the mold is opened, a preform is taken out, and an excess film is trimmed. Then, this preform is disposed in a mold for injection molding having a movable mold C and a fixed mold D, and then a film 8 with another design is brought into close contact with a recess of the mold C. After the mold is clamped, a transparent or translucent molten resin 7 is injected in the mold, the resin is solidified, then the mold is opened, the molding is taken out, and an excess film is trimmed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior material,
The present invention relates to an insert molded product decorated with a patterned film used as an interior for a building or the like.

Conventionally, there is an insert molded product using an insert film for decorating a material used as an interior material for an automobile or an interior material for a building. In particular, the design layer
Japanese Unexamined Patent Application Publication No. 9-131749 is known as one having a layer. A pattern layer is formed on both sides of the acrylic film, and the surface of the molded article is decorated by insert molding using a pattern-inserted film in which a fluorine film is laminated on one side (the front side of the product). In the publication, since the ink of the pattern on the front side of the molded article is exposed on the surface, it is protected from peeling or scratching of the ink due to contact, and furthermore, in order to improve chemical resistance, a fluorine film is stacked on the front side of the molded article. I have. In order to provide a pattern layer on both sides of the acrylic film as described in the publication, a pattern layer is first printed on one side of the acrylic film, and after drying the ink, the film is wound into a roll, and then the pattern layer is formed on the other side. And a step of winding the film into a roll after drying the ink is required. Providing the design layer on both sides of the film requires two printing steps, which increases the number of working steps and the manufacturing cost.

Further, the thickness of the acrylic film layer is in the range of 20 μm or more to 180 μm in the examples, but the three-dimensional appearance is insufficient.

[0004]

SUMMARY OF THE INVENTION The present invention provides an insert molded article having excellent appearance and decorative effects, such as having a three-dimensional appearance and a high-quality texture with depth, and which can be manufactured with high productivity, and a method of manufacturing the same. The purpose is to:

[0005]

Means for Solving the Problems As a result of intensive studies, the present inventor has found that it is effective to laminate a plurality of patterned films with the pattern as the base material side, and reached the present invention. .

That is, the present invention relates to (1) an insert-molded product comprising a base material and a laminated film with a pattern provided on the surface thereof, wherein the patterned film is provided on the substrate side of the film body layer. (2) The insert-molded article according to (1), wherein the insert-molded product has a design layer and a plurality of the design films, and (2) has a transparent or translucent intermediate layer between the design films. (3) Insert-molded article according to (1) or (2), wherein the patterns of at least two of the design layers are different or have the same pattern and are displaced, (4) a plurality of constituent films (1) The insert-molded product according to any one of (1) to (3), wherein the same material is used, (5) at least one set of the patterned film and the intermediate layer are acrylic resin. No Insert molding according to any Re,
(6) The insert molded product according to any one of (1) to (5), wherein the base material has a pattern similar to the pattern of the design film, (7) one design film is formed by a pair of split molds. And a step of disposing the film in a recess of one of the molds, and, after closing the mold, injecting the molten resin into the mold to form a preform. Disposing the preformed product in an injection molding die for main molding consisting of a pair of split dies; and disposing another patterned film in a concave portion of one of the molds. And a step of injecting a transparent (colorless, colored) or translucent molten resin between the film and the film.

(8) A step of arranging one piece of a film with a pattern in an injection mold having a pair of split molds and disposing the film in a concave portion of one of the molds;
Injecting the molten resin into a mold to form a preformed product; and forming an adhesive layer on a design layer of another patterned film and / or a film body layer of the preformed product, Laminating a film with a design on the main body layer of the film of the preformed product.

The insert molded article of the present invention is composed of a base material and a decorative film disposed on the surface thereof. In the present invention, the structure of the decorative film is important.

The decorative film in the insert molded article of the present invention has at least two or more patterned films. If necessary, a transparent or translucent intermediate layer may be provided between the patterned films.

By arranging a decorative film having a plurality of patterns on the surface of the base material as described above, the three-dimensional effect is more remarkable, and the warmth, softness, and depth can be enhanced as compared with the case where a single-layer pattern is provided. It is possible to provide an excellent calm feeling, that is, a high-quality texture.

The substrate on which the decorative film is provided is
It is composed of a thermoplastic resin. Since the design is located on the side of the base material, the design is always protected by the main body film of the film with the design. In the case where a transparent or translucent intermediate layer is provided between the patterned films, a required space is generated between the patterned films, and the three-dimensional appearance and texture of the patterned images are further improved. Further, when the insert molded product of the present invention is visually observed from the surface and then the viewpoint is moved, there is also an effect that the design appears to move due to the light interference effect. If necessary, one or more sets of a patterned film including an intermediate layer can be provided.

The design of the design layer of the plurality of design films used in the present invention may be the same or different.
In addition, even if the same pattern is arranged at a position shifted from each other, the three-dimensional appearance and texture of the design can be further enhanced. Also, the design appears to move due to the light interference effect.

The plurality of patterned films used in the present invention may be made of the same material or different materials, but by using the same material, it is possible to control the molding process (for example, one heating temperature is sufficient). ) Is simple, the workability is improved, and furthermore, the range of choice of the material of the intermediate layer is widened. In addition, compared to the conventional case where the design layers are provided on both sides of the film, the process is easy and the yield is good.

The material of the patterned film may be a transparent or translucent thermoplastic material. In particular, it is excellent in workability and can be easily processed even in a complicated shape. Acrylic films with a very wide choice of adhesives are preferred. The same applies to the middle layer,
An acrylic film or an acrylic resin is preferred. When both the patterned film and the intermediate layer are made of acrylic, they can be integrated without using an adhesive layer between them, so that the workability is further improved.

The pattern employed in the present invention is not particularly limited, and may be a pattern of natural materials such as wood grain, leather, natural stone or an artificial pattern, but a so-called flow pattern is also preferred. By providing the same pattern as the pattern of the design film on the surface of the substrate on which the design film is provided, for example, a flow pattern, the three-dimensional appearance and texture can be further improved.

The insert molded product of the present invention can be manufactured by an injection molding method. For example, (1) a step of arranging one piece of a film with a pattern in an injection molding die composed of a pair of split molds and disposing the film in a concave portion of one of the molds; A step of injecting the resin into a mold to form a preform, a step of arranging the preform in an injection mold for main molding consisting of a pair of split dies, and a film with another design A step of disposing a transparent (colorless, colored) or translucent molten resin between the preform and the another patterned film. Or (2) placing one film with a pattern in an injection mold composed of a pair of split molds, and placing the film in a recess of one mold. And after closing the mold, the molten resin Injecting and forming a preformed product, forming an adhesive layer on a design layer of another patterned film and / or a film body layer of the preformed product, and preforming the another patterned film. And a step of laminating the product film on the main body layer.

According to the production method (1), a required space can be provided between the film on the substrate side (lower side) and the upper film of the molded product, and this space is transparent or semi-transparent. Transparent thermoplastic resin can be installed, improving the three-dimensional appearance and texture of the design, and it is easy to insert molding using a film with a pattern that looks like the pattern moves by the light interference effect when moving the viewpoint Moreover, it can be manufactured reliably.

Further, according to the method (2), the injection molding process is performed only once at the time of preliminary molding, so that a relatively simple apparatus can be used as compared with the method (1).

In the insert molding method, an insert film in which a pattern layer made of a pattern ink or the like is formed on a film is placed in a mold for injection molding, and the insert film is sucked while being heated, and applied to the inner surface of the mold. This is a method in which a molten resin is injected into a mold after being shaped and clamped, and the resin is solidified so that the design layer side of the insert film is adhered to the resin molded product.

As is clear from the above description, the insert molded product of the present invention is provided with a plurality of insert films with a design on the surface of a resin molded product.

In the present invention, the film is for maintaining the design layer. Examples of the film include an acrylic film such as a polymethyl methacrylate film and a polyethyl methacrylate film, a polycarbonate film, a polyethylene terephthalate (PET) film,
A polyvinyl chloride film or the like can be used. In particular, the acrylic film has very good workability, so when it is used as a base sheet, even if the inner surface of the injection mold has a complicated shape, it can be heated or vacuumed. It can be deformed to follow the shape of the inner surface of the injection mold. In addition, since the acrylic film does not use any ink, the selection range of the ink and the adhesive is very wide. Furthermore, since the acrylic film has excellent light resistance and weather resistance, when the pattern layer is formed on the back surface as in the present invention, discoloration and damage can be suppressed.

Printing of a pattern on a film is performed by forming a pattern layer on one side of the film. This design layer is formed as a printing layer. The pattern layer is formed using a coloring ink containing a resin as a binder and a pigment or dye of an appropriate color as a coloring agent. As a method of forming the printing layer,
A normal printing method such as an offset printing method, a gravure printing method, and a screen printing method can be used. In particular, when performing multicolor printing or gradation expression, an offset printing method or a gravure printing method is suitable. In the case of single-color printing, a coating method such as a gravure coating method, a roll coating method, and a comma coating method can be employed.

The printing layer may be provided entirely or partially according to the design to be expressed.

The patterned film may be provided with an adhesive layer or an anchor layer as required. When the adhesion between the design layer and the resin molded product is poor, an adhesive layer is provided on the design layer surface. Also, when providing a colorless transparent, colored transparent or translucent thermoplastic resin layer between the patterned film and the patterned film, when the adhesiveness between the main body layer and the thermoplastic resin layer of the film is poor, or of the film When the adhesion between the design layer and the thermoplastic resin layer is poor, an adhesive layer is provided on the main body layer surface or the design layer surface. For the adhesive layer, an acrylic resin, urethane resin, polyester resin, polyamide resin, ethylene butyl alcohol resin, ethylene vinyl acetate copolymer, vinyl chloride / vinyl acetate copolymer, or the like may be used.

An anchor layer is provided when the adhesion between the main layer of the film and the design layer or the adhesion between the design layer and the adhesive layer is poor. For the adhesive layer and the anchor layer, the same printing method and coating method as used for the pattern layer can be used.

Next, the insert-molded article of the present invention and the method for producing the same will be described in more detail with reference to the drawings.

FIG. 1 is a perspective view of a finisher console showing an example of the insert molded product of the present invention. FIG.
FIG. 1B is a cross-sectional explanatory view along the line in FIG. 1A. FIG. 3 is a partially enlarged explanatory view of FIG. 2, 1 is a finisher console, 2 is a base portion of an insert molded product, 3 is a film with a pattern, 4 is a film body layer, 5 is a pattern layer, and 6 is a film adhesive layer. , 7 is a resin layer (intermediate layer), 8 is a patterned film, 9 is a film body layer, 10 is a patterned layer, and 11 is an adhesive layer of the film.

First, the first method, that is, a method of producing an insert molded product of the present invention by performing injection molding a plurality of times will be described.

As shown in FIG. 4 (a), one piece of the patterned film 3 is placed in an injection molding die composed of a movable mold A and a fixed mold B, and the film is sucked while being heated, and is moved. Closely contact the concave portion of the mold A. After closing the mold, the molten resin 2 is injected into the mold. After the resin has solidified, the mold is opened, the preform is removed, and the excess film is trimmed. Then
As shown in FIG. 4B, the preformed product is placed in an injection molding die for main molding including a movable die C and a fixed die D,
Another pattern-attached film 8 is sucked while being heated, and is brought into close contact with the concave portion of the movable mold C. After closing the mold, a transparent (colorless, colored) or translucent molten resin 7 is injected into the mold. After the resin has solidified, the mold is opened, the molded product is removed, and the excess film is trimmed.

The thickness of the resin layer (intermediate layer) 7 provided between the lower film and the upper film may be any thickness as long as an improvement in the three-dimensional appearance and texture of the design is recognized. In consideration of the fluidity of the resin in the mold, the thickness is preferably 1 mm or more. When the resin layer is thick, air bubbles are easily taken in during the flow of the resin, and a three-dimensional effect or the like, which is the object of the present invention, can be obtained. It is preferable that the thickness be 5 mm or less, since it is lost. More preferably, it is 2 mm or more and 2.5 mm or less.

When the moving distance of the resin in the mold is relatively short depending on the shape and size of the molded product, the thickness of the resin may be 1 mm or less.

A second method, that is, a method of manufacturing an insert molded product of the present invention by performing injection molding once using a film provided with an adhesive layer, will be described. , As shown in FIG.
A plurality of the patterned films are placed in an injection molding die including a movable die and a fixed die, and the film is suctioned while being heated, and is brought into close contact with the concave portion of the movable die. After closing the mold, the molten resin is injected into the mold. After the resin has solidified, the mold is opened, the preform is removed, and the excess film is trimmed.

Further, as shown in FIG. 5, a resin 12 for bonding is dissolved in an organic solvent and applied to the pattern layer 10 of another film 8 with a pattern to form an adhesive layer 11.
In advance. After heating the adhesive layer 11 of the patterned film 12, the main layer 4 of the film of the preformed product is heated.
And glue them together by pressing. Then trim the excess film.

In some cases, an adhesive resin is dissolved in an organic solvent and applied to the main body layer 4 of the film of the preformed product to form an adhesive layer 11. May be stacked and bonded by a press or the like.

As the resin of the adhesive layer used in this method,
Acrylic resin, urethane resin, polyester resin, polyamide resin, ethylene butyl alcohol resin, ethylene vinyl acetate copolymer, vinyl chloride / vinyl acetate copolymer, and the like can be used.

The thickness of the adhesive layer of the film to be laminated on the film of the preformed product may be any thickness as long as the three-dimensional appearance and texture of the design are improved. In consideration of workability in forming the adhesive layer on the film 8, the thickness of the adhesive layer 11 is preferably 0.5 mm or more and 1.5 mm or less.

In the case where the resin is injected into the mold for forming the intermediate layer as in the first method, there is a limit in reducing the thickness of the intermediate (resin) layer due to restrictions due to the mold. However, in the second method, an intermediate (adhesive) layer can be provided even thinner than the limit value of the first method.

In the case where three or more patterned films are provided on the front side of the molded article of the present invention, the films may be laminated only by the first method or the second method,
And the second method may be combined to laminate the films. Further, the plurality of patterned films used in the present invention may have the same or different thicknesses, and a surface treatment such as a grain may be applied to the front side of the main body layer of the patterned film.

Examples of the resin constituting the base material of the insert molded product of the present invention include acrylonitrile butadiene polystyrene copolymer (ABS), polypropylene (PP), and composite material (P) prepared by adding an additive to polypropylene.
Thermoplastic resins such as PC), polycarbonate (PC), and polyvinyl chloride (PVC) can be used, and these resins may be used in combination. A pigment may be added to the resin of the base material of the molded article. In particular, by adding one or several kinds of pigments that match the pattern of the patterned film, the pattern and pattern of the patterned film can be more effectively three-dimensionally and textured depending on the color and color tone of the substrate seen through the film. Can be pulled out.

Example 1 A polymethyl methacrylate film (125 μm) was used as an acrylic film. Using a pattern ink in which pigments of each color of white, yellow, and brown are mixed at a ratio of 2: 3 using a polyvinyl chloride resin as a binder, a marble-like pattern layer (6 μm) is formed on one surface of the film.
m) by printing and forming an acrylic resin adhesive layer (2 μm) on the pattern layer, and forming a patterned acrylic film (3,
8) was obtained.

The acrylic film 3 with the design is placed in an injection molding die composed of a movable mold and a fixed mold, and the acrylic film 3 with the design is heated at 140 to 160 ° C. and vacuum-sucked. In close contact. After closing the mold, while maintaining the mold temperature at 40 to 60 ° C., add 2 parts of ABS resin (transparent) 2 to which pigments such as white, yellow, and brown are added.
Heat to 00-250 ° C and melt, resin thickness 2-3mm
(FIG. 4 (a)). The resin had a flow pattern (marble tone) similar to the pattern of the patterned film. After the resin was solidified, the mold was opened, the preform was removed, and the excess film was trimmed.

Next, the preformed product and the acrylic film 8 with a design are arranged in an injection molding die for main molding comprising a movable mold and a fixed mold, and the acrylic film 8 with a design is heated at 140 to 160 ° C. Vacuum suction was carried out while heating, and it was brought into close contact with the concave portion of the movable mold. After closing the mold, set the mold temperature to 4
While maintaining the temperature at 0 to 60 ° C, the molten resin of the acrylic resin 7 (colorless and transparent) heated to 200 to 250 ° C has a resin thickness of 2 to 2 ° C.
2.5 mm was injected into the mold (Fig. 4
(B)). After the resin was solidified, the mold was opened, the insert molded product 1 of the present invention was taken out, and an excess film was trimmed.

Example 2 A polymethyl methacrylate film (125 μm) was used as an acrylic film. Using a pattern ink in which pigments of each color of white, yellow, and brown are mixed at a ratio of 2: 3 using a polyvinyl chloride resin as a binder, a marble-like pattern layer (6 μm) is formed on one surface of the film.
m) by printing and forming a patterned acrylic film (3,
8) was obtained.

The acrylic film 3 with the design is placed in an injection molding die comprising a movable mold and a fixed mold, and the acrylic film 3 with the design is heated at 140 to 160 ° C. and vacuum-sucked. In close contact. After closing the mold, while maintaining the mold temperature at 40 to 60 ° C., add 2 parts of ABS resin (transparent) 2 to which pigments such as white, yellow, and brown are added.
It was heated to 00 to 250 ° C., melted, and injected into a mold (the thickness of the resin was 2-3 mm). The resin had a flow pattern (marble tone) similar to the pattern of the patterned film. After the resin was solidified, the mold was opened, the preform was removed, and the excess film was trimmed.

Further, an acrylic resin for bonding is dissolved in a thinner, and a design layer 10 of another acrylic film 8 with a design is melted.
The acrylic film 12 was air-dried, and the thinner was removed beforehand.

The adhesive layer 11 of the patterned film was heated, superimposed on the main layer of the preformed film, and pressed to obtain a laminated product 1 (FIG. 5). Excess film was trimmed.

[0047]

As described above, according to the present invention,
It is possible to manufacture an insert molded product having a decoration excellent in three-dimensional appearance, texture, and texture with high productivity.

[Brief description of the drawings]

FIG. 1 is a perspective view of a finisher console of the present invention.

FIG. 2 is a cross-sectional explanatory view taken along line A in FIG. 1;

FIG. 3 is a partially enlarged explanatory view of FIG. 2;

FIG. 4 is a process chart of the method for producing an insert molded product according to the present invention. (A): Manufacturing process diagram of the preformed product (common to Examples 1 and 2) (B): Lamination process diagram of the patterned film of Example 1

FIG. 5 is a diagram showing a lamination process of a patterned film of Example 2.

Claims (8)

[Claims] Claims: 1. An insert molded product comprising a base material and a laminated film provided with a design provided on the surface thereof, wherein the design-equipped film has a design layer on the base material side of a film body layer, The insert molded product, comprising a plurality of the films with designs. 2. The insert molded article according to claim 1, further comprising a transparent or translucent intermediate layer between the patterned films. 3. The insert-molded product according to claim 1, wherein the patterns of at least two of the design layers are different or the patterns are the same and the positions are shifted. 4. The insert molded product according to claim 1, wherein a material of the plurality of constituent films is the same. 5. The insert molded product according to claim 1, wherein at least one set of the patterned film and the intermediate layer are made of an acrylic resin. 6. The insert-molded article according to claim 1, wherein the substrate has a pattern similar to the pattern of the patterned film. 7. A step of arranging a single patterned film in an injection molding die comprising a pair of split molds, and disposing the film in a concave portion of one of the molds;
Injecting the molten resin into the mold and molding a preformed product, placing this preformed product in a main molding injection molding die consisting of a pair of split dies, Disposing a film in a concave portion of one of the molds and injecting a transparent (colorless, colored) or translucent molten resin between the preformed product and the another patterned film. A method for producing an insert molded product, comprising: 8. A step of arranging one film with a design in an injection molding die composed of a pair of split molds, and disposing the film in a concave portion of one of the molds; Injection into a mold to form a preform,
A step of forming an adhesive layer on a design layer of another patterned film and / or a film body layer of the preformed product, and a step of laminating the another designed film on the body layer of the film of the preformed product. A method for producing an insert molded product, comprising: