JP2001180189A - Sheet to be formed and decorated simultaneously - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sheet formed and decorated simultaneously and not generating the interlaminar release on an interface between a metal gloss layer and a printed layer or a film in contact with the metal gloss layer. SOLUTION: The sheet 1 formed and decorated simultaneously is provided with a pattern layer 3 including at least the metal gloss layer 4 formed on a base sheet 2 and an overcoat layer 6 formed on the pattern sheet, and the 60 deg. glossiness value (x) is 30 or more when measured on the surface of the metal gloss layer 4 through the overcoat layer 6 in a measurement method based on the JIS K7105, and the film thickness of the overcoat layer 6 is in the range of 0.1 μm to 3000/x μm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a simultaneously decorated decorative sheet which can be used for decorating electric products, automobile parts, building materials and the like and which can provide decoration with excellent surface gloss.

[0002]

2. Description of the Related Art Conventionally, as a method of decorating the surface of an article, there is an insert molding method using a simultaneously decorated decorative sheet. With the insert molding method, a simultaneous decorative sheet with a pattern layer etc. formed on a base sheet is supplied into an injection molding die, and simultaneously with the formation of a three-dimensional molded product, the simultaneous decorative sheet is formed This is a method of decorating by integrally bonding to the product.

[0003] In particular, as a simultaneous decorative sheet capable of performing decoration with excellent surface gloss on a plastic molded product or the like, a pattern layer such as a metallic gloss layer is provided on a base sheet, and a pattern layer is provided thereon. There was an overlay film stuck.

[0004] The simultaneously-molded decorative sheet having such a structure is as follows.
Because it includes at least a metallic gloss layer as a design layer, it is possible to express a highly brilliant design using metallic luster,
Since the overlay film is laminated, the surface film can be maintained with high accuracy and the design layer can be protected.

[0005]

However, such a simultaneously decorated decorative sheet has the following problems.

That is, in the above-described simultaneously decorated decorative sheet, since heat applied during insert molding causes expansion and contraction of the base sheet and the overlay film, delamination occurs at the interface between the metallic gloss layer and the printing layer or film in contact therewith. There was a problem that sometimes. Moreover,
The frequency of occurrence of delamination tended to increase as the glossiness of the metallic gloss layer increased.

It is considered that delamination is caused by the following mechanism. That is, the overlay film slightly expands and contracts due to heat applied at the time of lamination with the base sheet and at the time of decorating at the same time as molding. The influence of the expansion and contraction is transmitted to the design layer, and a stress is applied to the design layer to peel it off.

On the other hand, when a metallic gloss layer is provided as a part of the design layer, the interface adhesion strength between the metallic gloss layer and the printing layer or film in contact therewith is lower than the interface adhesion strength between the printing layer or film. is there.

[0009] Therefore, stress that causes the pattern layer to peel off is concentrated on the metallic gloss layer having relatively low interfacial adhesion strength and the interface of the printing layer or the film in contact therewith, and delamination occurs.

Therefore, the present invention solves the above-mentioned problems, and causes delamination at the interface between the metallic gloss layer and the printing layer or film in contact with the metallic gloss layer, even if the metallic gloss layer has high gloss. An object of the present invention is to provide a simultaneous decorative sheet without molding.

[0011]

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.

In other words, the simultaneously decorated decorative sheet of the present invention has a pattern layer including at least a metallic gloss layer provided on a base sheet, and an overcoat layer is formed thereon. The 60-degree gloss value x measured on the layer surface through the overcoat layer is 30 or more according to the measurement method of Japanese Industrial Standard (JIS) K7105, and the thickness of the overcoat layer is 0.1 μm or more, (3
000 / x) μm or less.

In the above invention, the overcoat layer may be formed by a coating method.

In the above invention, the overcoat layer may be made of any one of a urethane acrylate resin, a cyanoacrylate resin, an acrylic resin, and a fluorine resin.

In the above invention, the surface of the overcoat layer may be configured to have hairline-shaped fine irregularities.

[0016]

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 the simultaneously decorated decorative sheet of the present invention. FIGS. 2 to 5 are cross-sectional views showing one process of forming and decorating simultaneously using the simultaneously decorating sheet of the present invention. In the figure, 1 is a simultaneously decorated decorative sheet, 2 is a base sheet, 3 is a pattern layer, 4 is a metallic gloss layer, 5
Is a pattern layer other than the metallic luster layer, 6 is an overcoat layer, 1
2 is a cavity mold, 13 is a core mold, 14 is a cavity surface, 15 is an end surface clamp member, 16 is an end surface clamp member drive source, 17 is a simultaneously formed decorative sheet transport member, 18 is a simultaneously formed decorative sheet cutting means, 19 Is a suction hole, 20 is a molding resin, and 21 is a decoration-simultaneously molded product.

The simultaneously decorated decorative sheet 1 of the present invention has a pattern layer 3 including at least a metallic gloss layer 4 provided on a base sheet 2 and an overcoat layer 6 formed thereon. , A 60-degree gloss value x measured on four surfaces of the metallic gloss layer through the overcoat layer 6 was 30 in the measurement method of Japanese Industrial Standards (JIS) K7105.
That is, the film thickness of the overcoat layer 6 is 0.1 μm or more and (3000 / x) μm or less (see FIG. 1).

The base sheet 2 may be a resin sheet such as a polypropylene resin, a polyethylene resin, a polyamide resin, a polyester resin, an acrylic resin, or a polyvinyl chloride resin; a metal foil such as an aluminum foil or a copper foil; Paper, coated paper, cellulosic sheets such as cellophane, or composites of the above sheets, such as those used as the base sheet 2 of the ordinary simultaneously formed decorative sheet, can be used.

The design layer 3 includes at least the metallic luster layer 4.

The metallic luster layer 4 is for expressing metallic luster, and is composed of a metal thin film or a brilliant ink film.

The metal thin film is made of aluminum, nickel,
Using metals such as gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, and alloys or compounds of these, formed by vacuum evaporation, sputtering, ion plating, plating, etc. Good to do.

The brilliant ink film is formed by a gravure printing method using a brilliant ink obtained by mixing a brilliant pigment such as an aluminum flake pigment or a pearl pigment with a resin binder.
Printing methods such as screen printing, reverse coating,
It is preferable to form by a coating method such as a dip coating method.

The metallic luster layer 4 may be partially formed. As an example of the case where the metallic luster layer 4 is partially formed, when the metallic luster layer 4 is formed of a metal thin film, a solvent-soluble resin layer is formed on a portion where the metallic luster layer 4 is not required, and then formed thereon. There is a method in which a metal thin film is formed on the entire surface, and a solvent washing is performed to remove an unnecessary metal thin film together with the solvent-soluble resin layer. 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. . When the metallic luster layer 4 is made of a brilliant ink film, it can be formed by patterning by a printing method.

The pattern layer 5 other than the metallic luster layer is a layer for expressing decoration in addition to the expression of metallic luster by the metallic luster layer 4. Specifically, for example, patterns such as characters and symbols, solid patterns, etc. And patterns such as wood grain patterns, stone grain patterns, and pseudo carbon pattern patterns. The design layer 5 other than the metallic gloss layer may be provided partially. The material of the design layer 5 other than the metallic luster layer includes polyvinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, and alkyd resin. It is preferable to use a colored ink containing a resin such as a binder and a pigment or dye of an appropriate color as a colorant. The pattern layer 5 other than the metallic gloss layer may be formed by a normal printing method such as an offset printing method, a gravure printing method or a screen printing method, or a coating method such as a roll coating method or a spray coating method. The thickness of the design layer 5 other than the metallic gloss layer is preferably 0.1 to 20 μm.
According to a normal printing method, this range is set. The pattern layer 5 other than the metallic gloss layer is formed between the metallic gloss layer 4 and the base sheet 2 or between the metallic gloss layer 4 and the overcoat layer 6.

The overcoat layer 6 protects the metallic luster layer 4 and smoothes the surface of the simultaneously molded decorative molded article 21. Examples of the overcoat layer 6 include a highly transparent polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin. It is preferable to use an ink consisting of: a coating method such as a roll coating method or a spray coating method, or a normal printing method such as a gravure printing method or a screen printing method.

In particular, the overcoat layer 6 is preferably formed by a coating method. The cohesive force of each component constituting the layer formed by the coating method,
Since it is weaker than the cohesive force of each component constituting the layer formed by the film, the interfacial adhesion to the other contacting layer tends to be relatively strong. Therefore, by forming the overcoat layer 6 by a coating method instead of using a film, the bonding force between the components constituting the overcoat layer 6 is slightly weakened,
The delamination can be prevented by balancing the interfacial adhesion with the design layer 3. Further, when the overcoat layer 6 is formed by a coating method, it is easy to pattern the overcoat layer 6 and to form fine irregularities on the surface of the overcoat layer 6. In particular, when it is desired to express a metallic pattern, a hairline pattern is often expressed by forming a large number of fine streaky irregularities on the surface of the overcoat layer 6. For this purpose, a method of coating the overcoat layer 6 with fine irregularities having a hairline shape, or a method of coating an overcoat material on a polyester film having hairline irregularities formed thereon, followed by a method of coating the metallic gloss layer 4 It is preferable to use a method of transferring the film to the base sheet 2 after forming the film.

By replacing the thick overlay film with the thin overcoat layer 6, the function of protecting the metallic luster layer 4, especially the abrasion resistance, is reduced. Therefore,
As the material of the overcoat layer 6, it is preferable to use a scratch-resistant resin such as an ultraviolet curable resin, a thermosetting resin, or an electron beam curable resin. Specifically, it is preferable to use any one of a urethane acrylate resin, a cyanoacrylate resin, an acrylic resin, and a fluorine resin.

The simultaneous decorative sheet 1 according to the present invention comprises:
The 60-degree gloss value x measured on four surfaces of the metallic gloss layer through the overcoat layer 6 is based on Japanese Industrial Standard (JIS) K7105.
And the thickness of the overcoat layer 6 is 0.1 μm or more and (3000 / x) μm or less.

It is technically difficult to form the overcoat layer 6 having a thickness of less than 0.1 μm. On the other hand, as the thickness of the overcoat layer 6 increases,
Since the degree of expansion and contraction tends to increase, the thickness of the overcoat layer 6 has an upper limit. In particular, the higher the glossiness of the metallic gloss layer 4 is, the lower the interfacial adhesion strength with the print layer or film is, so the upper limit of the thickness of the overcoat layer 6 is smaller.

The results obtained by variously changing the materials of the metallic gloss layer 4, the overcoat layer 6, and the base sheet 2 are as shown in Tables 1 to 3 shown in Examples, and the glossiness of the metallic gloss layer 4 and the overcoat layer It has been found that the upper limit of the thickness of No. 6 is almost inversely proportional in a certain range. That is, the upper limit of the thickness of the overcoat layer 6 is
If the 60 degree glossiness of x is x, then (3000 / x) μ
It was found that most of them were represented by m. This is presumably because the metal gloss layer 4 having a higher gloss has a higher metal content, and thus has a lower interface adhesion strength with another print layer or film. On the other hand, if the gloss value x is less than 30, the above-mentioned relationship is often not established.

By constructing the decorative sheet 1 at the same time as described above, it is possible to alleviate the stress for peeling off the design layer 3 and to eliminate the interface having relatively low adhesion strength. Even if the gloss is high, delamination at the interface with the metallic gloss layer 4 can be prevented.

Next, an example of a method of obtaining a simultaneously-decorated molded article 21 using the simultaneously-decorated sheet 1 having such a configuration will be described (see FIGS. 2 to 5).

First, the simultaneously-decorated sheet 1 is placed on the cavity mold 12 by the simultaneously-decorated sheet transport member 17.

The simultaneously-molded decorative sheet 1 is conveyed into a mold by a simultaneously-molded decorative sheet conveying member 17. The lower end surface of the simultaneously-decorated sheet 1 is pulled downward by the simultaneously-decorated-sheet conveying member 17 and conveyed between the three-dimensional frame-shaped clamp member and the cavity mold 12. Is fixed by an end face clamp member 15 provided below the cavity mold 12 (see FIG. 2).

At this time, the fixing position of the simultaneously-decorated sheet 1 may be aligned using a photoelectric tube sensor or the like so that the pattern of the simultaneously-decorated sheet 1 and the shape of the mold product are aligned.

Next, the concurrently forming decorative sheet transport member 17
Evacuation. The end face clamp member 15 releases the simultaneously decorated decorative sheet 1 and moves upward again. The feeding of the simultaneously-decorated sheet 1 is fixed, and the fixing of the simultaneously-decorated sheet 1 by the end face clamp member 15 is released. The simultaneous-decoration sheet 1 is fixed at the upper side so that the simultaneously-decorated sheet 1 is not unwound or rolled up, and the lower end is a free end. The length of the simultaneously decorated decorative sheet 1 along at least the cavity surface 14 having a three-dimensional shape is sent out. The simultaneously decorated decorative sheet 1 is appropriately heated and
It is fixed to the cavity mold 12 by performing suction. At this time, since the lower part of the simultaneously decorated decorative sheet 1 is a free end, it is not forcibly stretched or subjected to an excessive tension, and follows the three-dimensional shape of the cavity surface 14 without difficulty. After fixing the simultaneously-decorated sheet 1 to the cavity mold 12, the simultaneously-decorated sheet 1 is cut by the simultaneously-decorated sheet cutting means 18 such as a heat cutter provided above the cavity mold 12 (FIG. 3). reference).

Further, in order to heat the simultaneously-molded decorative sheet 1 to easily follow the cavity surface 14, the simultaneously-molded decorative sheet 1 may be heated by a heating means (not shown) such as an infrared heater. . Also, cavity surface 1
The simultaneous molding decorative sheet 1 may be formed by vacuum forming or pressure forming so as to conform to 4. A cavity mold 12 is formed around the simultaneous decorative sheet 1 by a frame-shaped clamp member (not shown).
, And simultaneous molding decorative sheet 1 and cavity mold 12
By vacuum-suctioning through the suction holes 19 provided in the cavity mold 12 while keeping the space closed, vacuum molding can be performed so that the simultaneously decorated decorative sheet 1 is along the cavity mold 12. Further, the simultaneous-decoration sheet 1 is fixed to the cavity mold 12 by a frame-shaped clamp member (not shown), the core mold 13 is closed, and the compressed air is sent out from the core mold 13, whereby the simultaneous-decoration sheet is formed. 1 can be pressure-formed so as to be along the cavity mold 12.

Next, the core mold 13 is closed, and the molding resin 20 is injected into the mold (see FIG. 4).
And molded resin 20 integrated with each other for simultaneous decorative molding 2
1 (see FIG. 5).

Examples of the molding resin 20 include a polyethylene resin, a polypropylene resin, an acrylic resin, a polystyrene resin, a polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin, an alloy resin of PC and ABS containing glass fibers, and the like. It is good to use.

After the molding resin 20 is solidified, the mold is opened, and the resin molded product to which the simultaneously-decorated sheet 1 has been integrated and adhered is taken out to obtain the simultaneously-decorated molded product 21.

The above-described method is an example of the molding means, and is not limited to this. For example, when the simultaneously-molded decorative sheet 1 is fed into the molding die, the single-sheet simultaneously-decorated sheet 1 may be fed one by one. In addition, the simultaneously decorated decorative sheet 1 may be one in which the periphery is cut in advance according to the shape of the molded product. In addition, after the simultaneous molding and decorating process, the excess simultaneous molding and decorating sheet 1 around the molded product may be cut and removed.

[0043]

EXAMPLES (Example 1) Using an ABS sheet having a thickness of 0.5 mm as a base sheet, metallic luster layers were formed using the following materials, and overcoat layers of various thicknesses were formed using cyanoacrylate. Was formed to obtain a simultaneously decorated decorative sheet.

The simultaneous molding and decorating process was performed using the simultaneously decorated decorative sheet thus obtained, and the relationship between the thickness of the overcoat layer and the delamination was measured. The following results were obtained.

[0045]

[Table 1]

Therefore, between the gloss of the metallic gloss layer and the thickness of the overcoat layer, a 60-degree gloss value (JIS K7) measured by passing the metallic gloss layer through the overcoat layer.
105) as x and the maximum thickness of the overcoat layer as y (μm), the maximum thickness y of the overcoat layer
= (3000 / x) was almost satisfied.

Example 2 A 0.5 mm-thick ABS sheet was used as a base sheet, and a chromium-deposited layer (gloss level 7
0) is used to form a metallic gloss layer, and the following materials having substantially the same degree of shrinkage in drying or curing during the formation of the overcoat layer are used, and overcoat layers of various thicknesses are formed and molded simultaneously. A decorative sheet was obtained.

The simultaneous molding and decorating process was performed using the thus-formed and simultaneously decorated sheet, and the relationship between the thickness of the overcoat layer and delamination was measured. The following results were obtained.

[0049]

[Table 2]

Therefore, if the degree of shrinkage of drying or curing during formation of the resin of the overcoat layer is substantially the same, it can be confirmed that the relationship between the type of the resin of the overcoat layer and the thickness of the overcoat layer is low. Was.

(Example 3) Using the following materials as a base sheet, a metallic luster layer was formed using a chromium vapor-deposited layer (gloss level 70), and overcoat layers having various thicknesses were formed using cyanoacrylate. Thus, a simultaneously decorated decorative sheet was obtained.

Simultaneous molding and decorating processing was performed using the thus-formed and simultaneously decorated sheet, and the relationship between the thickness of the overcoat layer and delamination was measured. The following results were obtained.

[0053]

[Table 3]

Accordingly, it was confirmed that the thickness of the base sheet and the thickness of the overcoat layer, and the type of the resin of the base sheet and the thickness of the overcoat layer had a low relationship.

Example 4 A 38 μm thick biaxially stretched polyethylene terephthalate film was subjected to hairline processing to obtain a base sheet having a surface having a hairline pattern of 3 to 8 μm in depth. Next, on the side of the base sheet where the hairline is formed, an overcoat layer made of a cyanoacrylate resin is formed to a thickness of 10 μm, a chromium vapor deposition layer is formed to a thickness of 4000 nm, and then a 3 μm thick vinyl acetate-based layer is formed. An adhesive layer made of a resin was formed.

The simultaneous decorative sheet obtained in this manner had a thickness of the overcoat layer of 2 to 7 μm, a glossiness of the chromium vapor-deposited layer measured through the overcoat layer of 55, and a gloss of the metallic gloss layer. The interfacial peel strength was very high.

When the simultaneous decorating process was performed using the simultaneously decorating sheet thus obtained, a molded article having a hairline pattern having a metallic luster on the surface was obtained.

[0058]

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

The simultaneously decorated decorative sheet of the present invention has a pattern layer including at least a metallic gloss layer provided on a base sheet, and an overcoat layer is formed thereon. The 60 degree gloss value x measured through the overcoat layer is based on Japanese Industrial Standard (JI
S) In the measurement method of K7105, it is 30 or more, the thickness of the overcoat layer is 0.1 μm or more, and (3000 /
x) Since it is not more than μm, even if the gloss of the metallic gloss layer is high, delamination does not occur at the interface between the metallic gloss layer and the printing layer or film in contact with the metallic gloss layer.

Further, since the overcoat layer can be formed by a coating method, a metallic luster design having a special effect such as a hairline 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 step of performing simultaneous molding and decorating processing using the simultaneously decorating sheet of the present invention.

FIG. 3 is a cross-sectional view showing one step of performing simultaneous forming and decorating processing using the simultaneous forming and decorating sheet of the present invention.

FIG. 4 is a cross-sectional view showing one step of performing simultaneous molding and decorating processing using the simultaneously decorating sheet of the present invention.

FIG. 5 is a cross-sectional view showing one step of performing simultaneous molding and decorating processing using the simultaneous molding and decorating sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Simultaneous shaping | decoration sheet 2 Substrate sheet 3 Pattern layer 4 Metallic gloss layer 5 Pattern layer other than metallic glossy layer 6 Overcoat layer 12 Cavity type 13 Core type 14 Cavity surface 15 End clamp member 16 End clamp member drive source 17 Simultaneous molding Decorative sheet conveying member 18 Simultaneous decorative sheet cutting means 19 Suction hole 20 Molded resin 21 Simultaneous decorative molded article

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3B005 EA04 EA08 EB01 EC01 FA04 FC02Y FC08Y FC09Y GA06 GB01 4F206 AA04 AA11 AA13 AD05 AD20 AF01 AF14 AH17 AH42 AH48 JA07 JB13

Claims (4)

[Claims] 1. A molded simultaneous decorative sheet in which a pattern layer including at least a metallic gloss layer is provided on a base sheet, and an overcoat layer is formed thereon, the metal gloss layer surface is measured at 60 ° through the overcoat layer. The gloss value x is 30 or more according to the measurement method of Japanese Industrial Standard (JIS) K7105, and the thickness of the overcoat layer is 0.1 μm.
As described above, the simultaneously decorated decorative sheet is (3000 / x) μm or less. 2. The simultaneously decorated decorative sheet according to claim 1, wherein the overcoat layer is formed by a coating method. 3. The sheet according to claim 1, wherein the overcoat layer is any one of a urethane acrylate resin, a cyanoacrylate resin, an acrylic resin, and a fluorine resin. 4. The simultaneously decorated decorative sheet according to claim 1, wherein the surface of the overcoat layer has fine hairline-shaped irregularities.