JP2002006105A - Antireflecting molded product and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an antireflecting molded product which is provided with an infrared ray transmission window part possessing excellent infrared ray transmission action and a transparent window part possessing excellent visibility, and its manufacturing method. SOLUTION: A partial infrared ray transmission layer 4 and a whole low reflecting layer 6 are formed at least on one side of a transparent substrate 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an antireflection molded product which can be used as a cover part of a display portion of a cellular phone, a video camera, a digital camera, an automobile device, and the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In a mobile phone, a video camera, a digital camera, an automobile device, etc., a display portion is
It is configured by a combination with a liquid crystal panel or an organic EL panel. In the display part, a pattern such as a transparent substrate or a border molded into a convex lens shape is formed for the purpose of preventing damage to the liquid crystal panel, enlarging the display of the liquid crystal panel, and decorating the vicinity of the liquid crystal panel. Covered by a transparent component made of a transparent substrate.

[0003] In the cover part, in addition to a transparent window portion through which a liquid crystal panel and the like disposed on the back can be seen through, a decorative design portion, and an infrared transmitting window portion for transmitting infrared rays are integrally formed. May form. The infrared transmission window covers an infrared light receiving element provided for controlling another electronic device or exchanging data with another electronic device.

[0004] The infrared transmitting window for such a purpose cuts light in the visible wavelength range, converts the dye that transmits only the near-infrared light into ink, forms a film, or forms a resin containing such a dye. (See FIG. 7).

[0005]

However, the above-mentioned cover component has a problem that when infrared communication is performed through an infrared transmission window, the transmitted near-infrared light is weakened. There is also a problem that visibility is reduced due to light reflection of the transparent window portion.

Accordingly, the present invention solves the above-mentioned drawbacks and provides an antireflection molded article having an infrared transmitting window portion having an excellent infrared transmitting effect and a transparent window portion having an excellent visibility, and a method of manufacturing the same. The purpose is to provide.

[0007]

Means for Solving the Problems The antireflection molded article of the present invention and the method for producing the same are constructed as follows in order to achieve the above object.

That is, the antireflection molded article of the present invention is:
On one surface of the transparent substrate, at least a partial infrared transmitting layer and an entire low reflection layer were formed.

Further, in the above invention, a configuration may be adopted in which an antifouling layer is formed on the low reflection layer.

Further, in the above invention, a configuration may be adopted in which a partial pattern layer of a pattern excluding a portion where an infrared transmitting layer is formed and a portion which becomes a transparent window is formed.

Further, in the method of manufacturing an antireflection molded article according to the present invention, a decorative sheet having at least a partial infrared-transmitting layer formed on a base sheet is placed in a mold such that the base sheet comes into contact with the cavity surface. Then, a transparent molten resin is injected into the mold to obtain an integrated product of the decorative sheet and the transparent substrate made of the resin, then the base sheet is peeled off, and then the low-reflection layer is entirely laminated. did.

A decorative sheet having at least a partial infrared-transmitting layer formed on a base sheet is placed in a mold, and a transparent molten resin is injected into the mold to comprise the decorative sheet and the resin. An integrated product with a transparent substrate was obtained, and then a low-reflection layer was entirely laminated.

[0013] In the above invention, the decorative sheet may include a protective layer on the entire surface, a partial design layer of a pattern excluding a portion where an infrared transmitting layer is formed and a portion which becomes a transparent window. The infrared ray transmitting layer and the entire adhesive layer may be formed at least on the base sheet.

Further, in the above invention, an antifouling layer may be formed on the low reflection layer.

[0015]

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

FIGS. 1 and 2 are sectional views showing one embodiment of the antireflection molded product of the present invention. 3 to 5 are cross-sectional views showing one embodiment of a decorative sheet used in the method for producing an antireflection molded product according to the present invention. FIG. 6 is a cross-sectional view showing one step of the method for manufacturing an antireflection molded product according to the present invention. In the figure, 1
Is a transparent substrate, 2 is an adhesive layer, 3 is a design layer, 4 is an infrared transmitting layer, 5 is a protective layer, 6 is a low reflection layer, 7 is an antifouling layer, 8 is a base sheet, 9 is an antireflection molded product, 11 Is a decorative sheet, 12
Is a mold.

The antireflection molded article 9 of the present invention has at least a partial infrared transmitting layer 4 and a low-reflection layer 6 formed on one side of the transparent substrate 1 (FIGS. 1 and 2).
reference).

In order to provide the infrared transmitting layer 4 and the like on the transparent substrate 1, it is preferable to use a simultaneous molding and decorating method using the decorating sheet 11. The simultaneous molding and decorating method includes a simultaneous molding and transferring method using a transfer material as the decorative sheet 11 and an insert method using an insert material as the decorative sheet 11.

In the simultaneous molding transfer method, a transfer material having a transfer layer formed of an infrared transmitting layer 4 or the like formed on a base sheet 8 is sandwiched in a mold 12 and a molten resin is injected into the mold 12.
At the same time as cooling to obtain a resin molded product, a transfer material is adhered to the surface of the molded product, the base sheet 8 is peeled off, and the transfer layer is transferred to the surface of the resin molded product to perform decoration.

In the insert method, an insert material in which an infrared transmitting layer 4 and the like are formed on a base sheet 8 is sandwiched in a mold 12, a molten resin is injected into the mold 12, cooled, and a resin molded product is cooled. At the same time, the decoration is performed by bonding an insert material to the surface of the molded product.

First, a molding simultaneous transfer method using a transfer material will be described.

The transfer material is such that a transfer layer comprising an infrared transmitting layer 4 and the like is provided on a base sheet 8 (see FIG. 3). Further, instead of forming all the layers formed on the transparent substrate 1 of the antireflection molded article 9 by the simultaneous molding transfer method, only the layers that are preferably formed by the simultaneous molding transfer method are formed by the simultaneous molding transfer method. The other layers may be formed separately. In particular, the protective layer 5, the design layer 3, and the infrared transmitting layer 4 are suitable for being formed by a molding simultaneous transfer method.

The base sheet 8 may be made of a polypropylene resin, a polyethylene resin, a polyamide resin,
What is used as a base sheet of a usual transfer material, such as a resin sheet of a polyester resin, an acrylic resin, a polyvinyl chloride resin, or the like, can be used.

When the transfer layer has good releasability from the base sheet 8, the transfer layer may be provided directly on the base sheet 8. In order to improve the releasability of the transfer layer from the base sheet 8, a release layer may be formed over the entire surface before providing the transfer layer on the base sheet 8.

Further, a protective layer 5 may be formed as required. The protective layer 5 is formed entirely on the base sheet 8 or the release layer. When the base sheet 8 is peeled off after the simultaneous transfer of the molding, the protective layer 5 is peeled off from the base sheet 8 or the release layer and becomes the outermost surface of the transferred object, and becomes a layer for increasing the surface strength of the antireflection molded article 9. . As the protective layer 5, a compound obtained by mixing a reactive diluent with a prepolymer or oligomer having a polymerizable double bond or a prepolymer or oligomer having an epoxy group and adding a photopolymerization initiator as necessary is used. Good. Specifically, a resin used as an ultraviolet curable resin or an electron beam curable resin may be used. Examples of the method for forming the protective layer 5 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.

When the protective layer 5 is not provided as a transfer layer, a release layer may be formed instead of the protective layer 5. The release layer is a layer for easily releasing the transfer layer from the base sheet 8. As the material of the release layer, acrylic resin,
In addition to polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, etc., vinyl chloride-vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, etc. It is preferable to use a copolymer of As a method for forming the release layer, there are 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.

If necessary, the design layer 3 is formed on the transparent substrate 1.
It may be formed on the top. The pattern layer 3 is made of an anti-reflection molded product 9
It is a layer for decorating. The pattern layer 3 is formed on the protective layer 5 or the release layer. The design layer 3 is usually formed as a printing layer. As a material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. ,
It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. The printing layer is partially provided in a pattern excluding a portion serving as an infrared transmitting window where the infrared transmitting layer 4 is formed and a portion serving as a transparent window.

The design layer 3 may be composed of a metal thin film layer or a combination of a printing 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. The metal thin film layer is usually formed partially. Further, when providing the metal thin film layer, a front anchor layer or a rear anchor layer may be provided in order to improve adhesion to other layers.

The infrared transmitting layer 4 is a layer for cutting light in the visible region and transmitting only light having a wavelength in the near infrared region.
The infrared transmitting layer 4 is formed by a printing method using an ink obtained by mixing a black dye or the like which does not transmit visible light and has excellent infrared transmittance in a binder such as an acrylic resin or an acrylic vinyl resin. Can be used.

Further, an adhesive layer 2 may be formed on the transparent substrate 1 in order to adhere the above layers. As the adhesive layer 2, a heat-sensitive or pressure-sensitive resin suitable for the material of the transparent substrate 1 is appropriately used.

For example, when the material of the transparent substrate 1 is an acrylic resin, it is preferable to use an acrylic resin. When the material of the transparent substrate 1 is a polyphenylene oxide / polystyrene-based resin, a polycarbonate-based resin, or a polystyrene-based blended resin, an acrylic resin, a polystyrene-based resin, a polyamide-based resin, or the like having an affinity for these resins may be used. I just need. Further, when the material of the transparent substrate 1 is a polypropylene resin, a chlorinated polyolefin resin,
Chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber,
Coumarone indene resin can be used. The method for forming the adhesive layer 2 includes a gravure coating method, a roll coating method,
There are a coating method such as a comma coating method and a printing method such as a gravure printing method and a screen printing method.

The structure of the transfer layer is not limited to the above-described embodiment. For example, when a material having excellent adhesiveness to the transparent substrate 1 is used as the material of the design layer 3, the adhesive layer 2 may be used. Can be omitted.

Next, a method of decorating the surface of a resin molded article as an object to be transferred using the above-described transfer material and the simultaneous transfer method by injection molding will be described.

First, a transfer material as the decorative sheet 11 is fed into a molding die 12 composed of a movable die and a fixed die (see FIG. 6). At this time, the sheet transfer material may be fed one by one, or a necessary portion of a long transfer material may be sent intermittently. When a long transfer material is used, it is preferable to use a feeder having a positioning mechanism so that the register between the design layer 3 of the transfer material and the molding die 12 coincides with each other. In addition, when the transfer material is intermittently fed, if the transfer material is fixed by the movable type and the fixed type after the position of the transfer material is detected by the sensor, the transfer material can always be fixed at the same position. This is convenient because no misalignment of the design layer 3 occurs.

After the molding die 12 is closed, a molten resin is injected and filled into the die 12 from a gate provided on the fixed die, and a transfer material is adhered to the surface of the transfer material simultaneously with the formation of the transfer object.

The resin that can be used for the transparent substrate 1 includes polystyrene resin, polyolefin resin, A
General-purpose resins such as BS resin, AS resin, and AN resin can be used. Also, general-purpose engineering resins such as polyphenylene oxide / polystyrene resin, polycarbonate resin, polyacetal resin, acrylic resin, polycarbonate-modified polyphenylene ether resin, polybutylene terephthalate resin, ultra-high molecular weight polyethylene resin, polysulfone resin, polyphenylene sulfide resin A super engineering resin such as a resin, a polyphenylene oxide resin, a polyarylate resin, a polyetherimide resin, a polyimide resin, a liquid crystal polyester resin, and a polyallyl heat-resistant resin can also be used.

The shape of the transparent substrate 1 may be a flat plate or may have a two-dimensional or three-dimensional curved surface.

After cooling the resin molded product as the transfer object,
The molding die 12 is opened and the resin molded product is taken out. Finally, the transfer material base sheet 8 is peeled off. In this way, only the transfer layer can be transferred to the molded article (FIG. 1).
reference).

Next, an insert method using an insert material will be described.

In order to obtain an insert material, the following method may be used.

The insert material is such that an infrared transmitting layer 4 and the like are provided on a base sheet 8 (see FIGS. 4 and 5). As the base sheet 8, the same sheet as that of the transfer material may be used. The protective layer 5, the design layer 3, the infrared transmitting layer 4, and the adhesive layer 2 may be formed in the same manner as in the case of the transfer material. In the case of the insert method, since the base sheet 8 is not peeled off, the protective layer 5 is formed on one surface of the base sheet 8 and the design layer 3, the infrared transmitting layer 4, and the adhesive layer 2 are formed on the other surface. (See FIG. 4), a protective layer 5, a design layer 3, and an infrared transmitting layer 4 are formed on one surface, and an adhesive layer 2 is formed on the other surface.
(See FIG. 5). Also, instead of forming all layers formed on the transparent substrate 1 of the antireflection molded product 9 by the insert method, only layers suitable to be formed by the insert method are formed by the molding simultaneous transfer method. This layer may be formed separately as in the case of the molding simultaneous transfer method.

As described above, the insert material can be obtained. Next, a method of using the insert material will be described.

The insert material, which is the decorative sheet 11, is placed between the core mold having the gate and the cavity mold having the concave portion by using an insert material feeding device or the like. Or fix around. When the molding shape is deep drawing, the insert material may be heated and softened by a heat source, and may be closely attached to the surface of the cavity mold by vacuum suction from the cavity mold side. The cavity mold and the core mold are clamped to form a closed space between the insert material and the core mold. The molten resin is injected into this space. If the cavity mold and the core mold are opened, a molded product in which the insert material and the molding resin are integrated can be obtained.

Also, insert molding can be performed as follows. First, the insert material is fixed to a preforming mold having a concave portion for deep drawing by means of a clamp or the like, and then the insert material is heated and softened by a heat source and vacuum-sucked from the preforming mold side to form a preforming mold. Adhere to the surface. Next, the vacuum suction is released, and the insert material is taken out of the preforming mold. In this way, a deep drawn insert material can be obtained. Next, the preformed insert material is placed between a core mold having a gate and a cavity mold having a concave portion for deep drawing, and is fixed in or around the cavity mold by means such as a clamp. Next, the cavity mold and the core mold are clamped to form a closed space between the insert material and the core mold. If the molten resin is injected into this space and the cavity mold and the core mold are opened, the insert material and the molding resin can be integrated.

The low reflection layer 6 is a layer for preventing reflection of the transparent substrate 1.

The low refractive material used for the low reflection layer 6 includes
Metal oxides such as magnesium fluoride and silicon oxide can be used. Further, an organometallic compound containing at least one of silica and organopolysiloxane can also be used. Further, a porous body of these organometallic compounds can also be used. It is also possible to use an organic compound such as a fluorine-based synthetic resin.

The low-reflection layer 6 may be composed of silicon oxide or aluminum oxide having fine pores dispersed in silicon oxide and used as a single layer, magnesium fluoride as a single layer, or a titanium oxide layer / oxide. Silicon layer 2
It can be used as a low-reflection layer 6 having a layer structure,
4 like silicon oxide layer / titanium oxide layer / silicon oxide layer
The low-reflection layer 6 having a multilayer configuration using multiple interference, such as the low-reflection layer 6 having a layer configuration, may be used.

The method of manufacturing these low reflection layers 6 is as follows.
There are a vacuum deposition method, a sputtering method, an ion plating method, and the like. Alternatively, an organic metal compound such as a metal alcoholate or a metal chelate is applied onto the transparent substrate 1 by an immersion method, a printing method, a coating method, or the like, and thereafter,
There is also a method of obtaining a low reflection layer 6 by forming a metal oxide film by light irradiation or drying.

The thickness of the low reflection layer 6 may be appropriately selected in the range of 0.01 to 2 μm. Depending on the refractive index of the low refractive material, these film thicknesses can be represented by the general formula n × d = λ / 4 or the general formula n × d = 3λ / 4 (where n is the refractive index of the low refractive material,
d is the thickness of the low-refractive material, and λ is the low reflection center wavelength).

Further, an antifouling layer 7 may be provided if necessary. The antifouling layer 7 is a layer provided on the low reflection layer 6 in order to prevent contamination of the antireflection molded article 9. As the antifouling layer 7, it is preferable to use a surfactant having fluorine in a terminal group. The antifouling layer 7 may be provided by a coating method, a dipping method, a vacuum deposition method, or the like. The film thickness of the antifouling layer 7 is
It is preferable to be as thin as possible. This is because, if the thickness of the antifouling layer 7 is large, the light transmittance of the antireflection molded article 9 decreases.

As described above, since the low reflection layer 6 is formed so as to overlap with the infrared transmission layer 4, the low reflection layer 6 is formed.
Reduces the reflection of light in the near-infrared region, improves the light transmittance in the near-infrared region of the infrared transmitting window portion by about 2 to 8%, and enables reliable infrared communication.
In addition, since the low reflection layer 6 is formed also in the transparent window portion, light reflection is reduced and visibility is improved.

[0052]

EXAMPLE A full release layer made of an acrylic resin was formed on a polyester film by a gravure printing method, and then a portion made of an acrylic vinyl resin was formed in a portion except for a transparent window portion and an infrared ray transmitting window portion of a mobile phone. A partial black pattern layer is formed by a gravure printing method, and then an infrared transmitting layer made of an acrylic vinyl resin containing an infrared transmitting dye is formed on the infrared transmitting window portion by a gravure printing method, and then made of an acrylic resin. A transfer material was obtained by forming an entire adhesive layer by a gravure printing method.

Next, a transfer material is set between injection molds for forming a cover part for a mobile phone, and after clamping,
Inject acrylonitrile styrene resin, after cooling and solidifying,
The mold was opened to take out the molded product, and the base sheet of the transfer material was peeled off and removed.

Next, the SiO ₂ / Z was formed by the EB evaporation method.
rO ₂ + TiO ₂ / SiO ₂ / ZrO ₂ / SiO ₂ of 5
A low-reflection layer composed of a layer was entirely formed on both surfaces of the molded article.

Next, a fluorine-based silane compound was deposited on the low-reflection layer on the surface side of the molded article to form an antifouling layer.

The cover part for a portable telephone thus obtained was integrally provided with an infrared transmitting window portion having excellent infrared transmittance and a transparent window portion having excellent visibility.

[0057]

Since the present invention employs the above-described configuration, the following effects can be obtained.

Since the antireflection molded article of the present invention has at least a partial infrared-transmitting layer and a low-reflection layer formed entirely on one surface of a transparent substrate, light having a wavelength in the infrared region can be obtained. It is provided with an infrared transmission window portion having an excellent infrared transmission function having an improved transmittance and a transparent window portion having an excellent visibility integrally.

Further, according to the method for producing an antireflection molded product of the present invention, a decorative sheet having at least a partial infrared-transmitting layer formed on a base sheet is placed in a mold so that the base sheet is in contact with the cavity surface. Then, a transparent molten resin is injected into the mold to obtain an integrated product of the decorative sheet and the transparent substrate made of the resin, and then the base sheet is peeled off, and then the low-reflection layer is entirely laminated. It is possible to easily obtain an anti-reflection molded product integrally having an infrared transmitting window portion having an excellent infrared transmitting effect and having a transparent window portion having an excellent visibility and having an improved transmittance of light having a wavelength in an outer band. .

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of an antireflection molded product according to the present invention.

FIG. 2 is a sectional view showing an embodiment of the antireflection molded product of the present invention.

FIG. 3 is a cross-sectional view showing one embodiment of a decorative sheet used in the method for producing an antireflection molded product according to the present invention.

FIG. 4 is a cross-sectional view showing one embodiment of a decorative sheet used in the method for producing an antireflection molded product according to the present invention.

FIG. 5 is a cross-sectional view showing one embodiment of a decorative sheet used in the method for producing an antireflection molded product of the present invention.

FIG. 6 is a cross-sectional view showing one step of the method for manufacturing an antireflection molded product according to the present invention.

FIG. 7 is a sectional view showing a conventional example of an antireflection molded product.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Transparent substrate 2 Adhesive layer 3 Design layer 4 Infrared transmitting layer 5 Protective layer 6 Low reflective layer 7 Antifouling layer 8 Base sheet 9 Antireflective molded article 11 Decorative sheet 12 Mold

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) B29L 7:00 B29L 9:00 9:00 11:00 11:00 G02B 1/10 A F term (reference) 2K009 AA04 AA05 AA07 BB14 BB24 CC03 CC06 DD03 EE05 FF01 4F100 AK12D AK12J AK25B AK25C AK27D AK27J AL01D AR00B AR00C AR00D AT00A BA04 BA07 BA10A BA10E DB20 DC30B DC30C EC041 EG001 EH361 EH461 EH662 EJ301 EJ911 GB41 HB00 HB31B HB31C JD10B JL02 JL06D JN01A JN01D JN06C JN06E 4F206 AD05 AD10 AG01 AG03 AH26 AH33 AH42 JA07 JB13 JB24

Claims (7)

[Claims] 1. An anti-reflection molded article characterized in that at least a partial infrared transmitting layer and an entire low-reflection layer are formed on one surface of a transparent substrate. 2. The antireflection molded article according to claim 1, wherein an antifouling layer is formed on the low reflection layer. 3. The anti-reflection molding according to claim 1, wherein a partial pattern layer is formed except for a portion where the infrared ray transmitting layer is formed and a portion where the transparent window is formed. Goods. 4. A decorative sheet having at least a partial infrared transmitting layer formed on a base sheet is placed in a mold so that the base sheet is in contact with the cavity surface, and a transparent molten resin is injected into the mold. A method for producing an anti-reflective molded product, comprising: obtaining an integrated product of a decorative sheet and a transparent substrate made of a resin; removing the base sheet; and then laminating a low-reflection layer over the entire surface. 5. A decorative sheet in which at least a partial infrared transmitting layer is formed on a base sheet is placed in a mold, and a transparent molten resin is injected into the mold to be composed of the decorative sheet and the resin. A method for producing an antireflection molded product, comprising obtaining an integrated product with a transparent substrate, and then laminating a low-reflection layer over the entire surface. 6. A decorative sheet comprising a protective layer, a partial pattern layer excluding a portion where an infrared transmitting layer is formed and a portion serving as a transparent window, and a partial infrared transmitting layer. The method for producing an antireflection molded product according to any one of claims 4 to 5, wherein the entire adhesive layer is formed on at least the base sheet. 7. The method according to claim 4, wherein an antifouling layer is formed on the low reflection layer.