JP2002192649A - Bright decorative sheet and method for producing bright decorated article using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the reduction of the glossiness of a bright layer caused by macro-cracks and the transparency of the bright layer, etc. SOLUTION: In a bright decorative sheet, the specular glossiness Gs (60 deg.) measured by JIS Z8741 of the bright decorative sheet 5 after thermoforming in which at least the bright layer 3 is formed on a thermoformable base material sheet is kept to be at least 43% of the glossiness of the decorative sheet 5 before the thermoforming.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior part such as a console panel, a center cluster, and a switch base, a painted side mat guard, a bumper, and the like.
The present invention relates to a glittering decorative sheet for decorating automotive exterior parts such as wheelcaps and malls, home electric appliances, mobile phones, and the like, and a method of manufacturing a glittering decorative article using the sheet.

[0002]

2. Description of the Related Art Conventionally, a glittering decorative sheet having a glittering layer formed on a thermoformable base sheet is softened by heating in advance outside or in an injection mold, and then vacuum or softened. A method of manufacturing a glittering decorative product in which a molding resin is injected into a cavity after being deformed by pressurized air, closed, and a glittering decorative sheet and an injection-molded product are integrally bonded has been implemented. Note that “thermoforming” means that the glittering decorative sheet is softened by heating and deformed into an arbitrary shape.
For example, after the glittering decorative sheet is softened by heating in advance, and then deformed by a vacuum mold at another place, a planar heat source is arranged on both the front side and the back side of the glittering decorative sheet. Then, after heating, (1) the glittering decorative sheet itself moves from the planar heat source and moves to the place where the vacuum forming die is located, or (2) the planar heat source moves and the heat source There was a case where a vacuum forming die came instead of the above.

[0003]

However, in the case of (1), since the surface temperature is lowered during the movement of the glittering decorative sheet, when the glittering decorative sheet reaches the vacuum forming die, the softening of the glittering decorative sheet becomes difficult. In some cases, the degree was reduced and the desired three-dimensional shape could not be obtained. In the case of (2), the planar heat source moves to remove the ambient temperature in the vicinity of the glittering decorative sheet. In some cases, the degree of softening was low, and the desired three-dimensional shape could not be obtained. As described above, if the degree of softening is lowered once after being pulled up and before vacuum forming, the glittering layer cannot follow the shrinkage of the base sheet generated at that time, so that the glittering layer has wrinkles. Microcracks were generated. For this reason, the glossiness of the glittering layer is reduced by half due to the microcracks, the glittering layer of the glittering decorative sheet is transparent, and the appearance is impaired. In addition, the moisture resistance is deteriorated due to the microcracks and the metal layer constituting the glittering layer However, physical properties such as corrosion of the steel became poor.

[0004]

Means for Solving the Problems In order to solve the above problems, the following has been made. As described in claim 1, the specular gloss Gs (6) after thermoforming of a glittering decorative sheet having at least a glittering layer formed on a thermoformable base sheet.
0 °) is a glittering decorative sheet that retains 43% or more before thermoforming in the measurement method specified in JIS-Z8741. As described in the second aspect, the condition of the thermoforming may be such that the glittering decorative sheet is softened by heating, and then formed within 5 seconds by vacuum or pressure forming to be deformed. . As described in claim 3, the glittering layer is formed by using any one of aluminum, chromium, indium, tin, nickel, gold, silver, copper and platinum, or an alloy thereof. May be a glittering decorative sheet. As described in claim 4, after the glittering decorative sheet according to any one of claims 1 to 3 is softened by heating in advance, the sheet is deformed by vacuum or pressurized air, and then set in an injection molding die. After closing the mold,
A molding resin is injected into the cavity, and the glittering decorative sheet and the injection-molded product are integrally bonded to each other. As described in claim 5, the glittering decorative sheet according to any one of claims 1 to 3 is set in an injection molding die, and is softened by heating in the injection molding die, and then vacuum or A method of manufacturing a glittering decorative article in which the resin is deformed by pressurized air and adhered to a mold, and after closing the mold, a molding resin is injected into the cavity and the glittering decorative sheet and the injection molded article are integrally bonded.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The glittering decorative sheet of the present invention
It is assumed that at least a glitter layer is formed on a thermoformable base sheet.

[0006] The material of the thermoformable base sheet is a material which can be softened by heating and then deformed by vacuum or compressed air to obtain a desired three-dimensional shape. Specifically, acrylic resin, ABS, etc. Resin, polypropylene resin,
Examples include polycarbonate resin, polybutylene terephthalate resin, and polyvinyl chloride resin. The base material sheet has a thickness of 100 to 750 × 10 ⁻³ mm, particularly 200
５００500 × 10 ⁻³ mm is preferred. This is because wrinkles and tears are less likely to occur, and it is easy to follow fine grooves formed on the surface of a vacuum mold or the like. The hardness of the base sheet is 2B ~
2H is preferred. If it is smaller than 2B, it is too soft and easily dented or stretched even if it is deformed into a three-dimensional shape, resulting in poor shape retention. If it is larger than 2H, it is too hard to be deformed into a three-dimensional shape, and forcible deformation causes whitening. This is because it becomes a defective product. The degree of stretching of the base sheet is 1
0/1000 or less is preferable. If the ratio is larger than 10/10000, the glittering decorative sheet easily curls and cannot be set in the injection mold. When the base sheet side is integrally bonded to the injection molded article instead of the glittering layer side, the base sheet may or may not be provided with an adhesive layer. It is considered that the adhesive layer may not be provided in some cases because only the outermost layer of the base sheet itself melts and becomes adhesive due to the heat of the molding resin described later, and thus it is considered to adhere to the molding resin. In order to facilitate adhesion, it is effective to match the respective resin systems of the material of the base sheet and the material of the molding resin.

The glittering layer is preferably a vapor deposited layer composed of any one of aluminum, chromium, indium, tin, nickel, gold, silver, copper and platinum, or an alloy thereof. The thickness of the glittering layer is 100 to 800 × 1
0 ^-3 mm range is preferred. The film thickness is 100 × 10 ⁻³
If the thickness is smaller than 1.0 mm, it is difficult to obtain a required metallic luster, and if the thickness is larger than 800 × 10 ⁻³ mm, the film becomes too hard to be easily deformed into a three-dimensional shape. Furthermore, 300-60
A range of 0 × 10 ⁻³ mm is more preferable. Thickness 30
If the thickness is smaller than 0 × 10 ⁻³ mm, transparency may occur when deformed into a three-dimensional shape, and the film thickness is 800 × 10 ^−3.
If it is larger than mm, the adhesion with the adjacent layer becomes weaker with the passage of time, and delamination occurs. As a method for forming the glittering layer, there are a vacuum evaporation method, a sputtering method, an electron beam method, and the like.

[0008] The glittering decorative sheet of the present invention further comprises:
The mirror gloss Gs (60 °) after thermoforming is JIS-Z8
741 in the measuring method defined in
% Or more. Specular gloss Gs (60
(°) means that light from a standard light source is applied to a data surface at a specified angle, and the specular reflection component is measured by a light receiver. Each of the incident angle and the reflection angle is 60 ± 0.1.
The angle is set to 1 °. When the specular glossiness is measured by the JIS code measuring method, the occurrence of the microcracks can be easily confirmed. The condition that the specular gloss Gs (60 °) is maintained at 43% or more is that a decorative sheet heated at a temperature capable of being deformed into a desired three-dimensional shape by thermoforming is generated in the glittering layer. Minimizing the occurrence of micro cracks
This is because the value is for maintaining the glossiness of the design.
As an example of the thermoforming conditions, the heating temperature is 400 to 75.
There is an example in which a glittering decorative sheet is heated and softened using a heat source set at 0 ° C., and then deformed by vacuum or pressure forming within 5 seconds. The heating temperature is set to 400 to 750 ° C. in order to prevent insufficient heating of the glittering layer due to heat radiation, particularly when heating from the glittering layer side. Also, the reason for deforming by vacuum or pressure forming within 5 seconds is that if the time from heating and softening the glittering decorative sheet to vacuum or pressure forming is longer than 5 seconds, the glittering decorative sheet will be brightened and decorated. This is because the shrinkage of the sheet starts and microcracks occur in the glittering layer. The heating time varies depending on the material of the base sheet of the glittering decorative sheet. For example, as the thickness of the base sheet increases, the heating time also increases. In order to soften the glittering decorative sheet by heating in advance, it can be performed by approaching a hot plate, blowing hot air, or irradiating far infrared rays. Further, in order to deform the glittering decorative sheet, a method of deforming by utilizing a pressure difference of air by vacuum or pressurized air can be used.

An adhesive layer 2 may be formed between the base sheet 1 and the glittering layer 3. The purpose of the adhesive layer 2 is to improve the adhesion strength between the base sheet 1 and the glittering layer 3. In particular, for automotive applications, resistance to vibration, impact, adhesion of water and oil is required, and therefore it is preferable to form an adhesive layer for maintaining resistance. As the material of the adhesive layer, a vinyl chloride-vinyl acetate copolymer resin or the like may be used. When the material of the base sheet is a polypropylene resin, a urethane resin or the like may be used as the material of the adhesive layer. The adhesive layer may be formed by a known printing method such as a gravure printing method, or a known coating method such as a gravure coating method, a silk coating method, a lip coating method, and a reverse coating method.

[0010] A surface protective layer may be further formed on the glittering layer. The purpose of the surface protective layer is to improve the rust resistance, crack resistance, weather resistance and damage resistance of the glittering layer. In particular, for use in automobiles, resistance to vibration, impact, adhesion of water and oil is required, and it is preferable to form a surface protective layer to maintain the resistance. Examples of a material for forming the surface protective layer by a printing method or a coating method include an acrylic resin and an acrylic urethane resin. An electron beam-curable or ultraviolet-curable material in which a photopolymerization initiator is contained in these resins may be used. As a printing method, there is a known printing method such as a gravure printing method. As the coating method, there are known coating methods such as a gravure coating method, a silk coating method, a lip coating method, and a reverse coating method. When the surface protective layer is formed as a thermoformable sheet, examples of the material include an acrylic resin, a polycarbonate resin, and a fluorine-containing acrylic resin. A sheet obtained by laminating a sheet made of a polycarbonate resin and a sheet made of a polybutylene terephthalate resin may be used as the surface protective layer.

When the surface protective layer is formed as a constituent layer of the transfer layer, a release layer for facilitating the separation between the transfer layer and the base sheet can be used as the surface protective layer. In this case, examples of the material include an acrylic resin, a cellulose resin, and a urethane resin. Lacquer (acrylic resin, acrylic resin, polyol resin, acrylic resin, acrylic urethane resin) may be used.

As a method for forming the above-mentioned glittering layer, adhesive layer and surface protective layer on a thermoformable base sheet, a stretched base sheet prepared separately from the thermoformable base sheet may be used. A glitter layer, an adhesive layer, and a surface protective layer are once formed by printing or the like to form a transfer sheet, and then the glitter layer, the adhesive layer, and the surface protective layer are formed from the transfer sheet on a thermoformable base sheet. There are a method of transferring and a method of directly printing a glittering layer, an adhesive layer, and a surface protective layer on a thermoformable base sheet.

Next, a method of manufacturing the glittering decorative article of the present invention will be described. As one method, after softening the glittering decorative sheet by heating in advance, deforming it by vacuum or compressed air, setting it in an injection molding mold, closing the mold, injecting molding resin into a cavity, This is to integrally bond the decorative sheet and the injection molded product. In order to soften the glittering decorative sheet by heating before setting it in the injection molding die, first, as shown in FIGS. The upper heat source 8 and the lower heat source 9 are moved in parallel by the slide device 13 to cover the upper and lower surfaces of the glittering decorative sheet 5 whose both ends or the periphery are fixed by the clamps 10. Heating is 400-75
The hot plate heated to 0 ° C. is heated for about 6 to 10 seconds at an interval of about 10 cm from the surface of the glittering decorative sheet 5 (see FIG. 3). After being softened by heating, the upper heat source 8 and the lower heat source 9 are moved in parallel by the slide device 13 so that the upper heat source 8 and the lower heat source 9 are brilliantly decorated.
Return to the original standby position from the upper and lower surfaces (see FIG. 4). Immediately, the vacuum forming die 11 waiting below is moved upward to press the convex portion of the vacuum forming die 11 against the glittering decorative sheet and to suck the same through the vacuum suction hole 12 to form the vacuum forming die 1.
The first protrusion is deformed along the outer surface (see FIGS. 4 and 5). If necessary, the glittering decorative sheet 5 may be evacuated from above the vacuum forming die 11. In any of the above states, it is preferable that the glittering decorative sheet 5 be kept stationary. This is to prevent the degree of softening from lowering or fluttering due to the wind due to the movement of the glittering decorative sheet itself as much as possible. In order to set the deformed glittering decorative sheet in the injection molding die 14, it is preferable to fit the concave or convex part of the injection molding die (see FIG. 6).

As another method, a glitter decorative sheet is set in an injection molding die, softened by heating in the injection molding die, and then deformed by vacuum or pressurized air to adhere to the die. After closing the mold, there is a method of injecting a molding resin into the cavity and integrally bonding the glittering decorative sheet and the injection molded product. In this case, there is no need to process the injection molding die to install a vacuum device or a compressed air device, or to install a device such that the heating device moves in and out of the die.
It is simple as an injection molding device and the molding time can be shortened. When heating in an injection mold, heating is 400 to
A heat source (for example, a hot plate) heated to 750 ° C. is introduced into the injection mold, and the glittering decorative sheet pressed with a clamp around the concave portion of the female mold of the injection mold. Get closer. Next, from the surface of the glittering decorative sheet,
Heat at intervals of 0 cm for about 6-10 seconds. The heating may be performed only from the base sheet side of the glittering decorative sheet, or only from the decorative layer surface side, or may be performed from both the base sheet side and the decorative layer side of the glittering decorative sheet. . After softening by heating, the heat source is moved from the inside of the injection mold to the outside, and immediately deformed by vacuum suction and, if necessary, by compressed air. The vacuum suction may be performed by sucking through the vacuum suction holes 12 formed on the surface of the female concave portion, attracting the glittering decorative sheet 5 softened by heating, and causing it to follow the inner surface of the female concave portion. The pressurized air is preferably formed by injecting hot air from a pressurized air hole formed on the surface of the male convex portion, and pressing the glittering decorative sheet softened by heating against the inner surface of the female concave portion so as to make close contact (not shown). .

Molding resin 6 injected into the cavity after closing the mold
Examples thereof include a heat-resistant ABS resin, a polycarbonate resin, a polypropylene resin, and an alloy of an ABS resin and a polycarbonate resin. A glitter decoration article in which the glitter decoration sheet and the injection molded article are integrally bonded is obtained.

[0016]

Example 1 A glittering decorative sheet in which a glittering layer composed of a chromium vapor-deposited layer was formed on a thermoformable base sheet made of an ABS resin having a thickness of 0.35 mm by thermal lamination was obtained. The 60 ° specular gloss Gs (60 °) defined by JIS-Z8741 of the glittering decorative sheet was 381 or more. The brilliant decorative sheet was evaluated by a simple vacuum forming machine Formech 450 having a heat source under the following conditions. From this evaluation result, in the case of a glittering decorative sheet using a thermoformable base sheet made of an ABS resin having a thickness of 0.35 mm, vacuum suction is performed within 5 seconds after moving the heat source, and the mirror gloss after thermoforming is obtained. It can be seen that when the degree Gs is maintained at 43% or more before the thermoforming, a formed glittering decorative sheet having high gloss can be obtained without generating microcracks. In the table, "drawing property" refers to the shape following property of the surface of the mold when the glittering decorative sheet is softened and sucked in vacuum.

[0017]

[Table 1]

[0018]

The glitter decorative sheet of the present invention has a specular gloss Gs (60) after thermoforming of a glitter decorative sheet having at least a glitter layer formed on a thermoformable base sheet.
°) in the measurement method specified in JIS-Z8741 to maintain 43% or more before thermoforming. Further, the method for manufacturing a glittering decorative article of the present invention, before or after setting the glittering decorative sheet in the injection molding die, deformed by vacuum or air pressure, after closing the mold,
The molding resin was injected into the cavity, and the glittering decorative sheet and the injection molded product were integrally bonded.

Therefore, in the glitter decorative sheet of the present invention, even if the degree of softening is raised once and then lowered before vacuum forming, the shrinkage of the base sheet occurring at that time causes the glitter layer Can follow, so that wrinkle-like microcracks do not occur. For this reason, the glossiness of the glittering layer is reduced by half due to the microcracks, and the glittering layer of the glittering decorative sheet is transparent and the appearance is impaired, and the microcracks deteriorate the moisture resistance and the metal constituting the glittering layer A decrease in physical properties such as the layer being easily corroded can also be suppressed.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of a glittering decorative sheet of the present invention.

FIG. 2 is a cross-sectional view showing an example of a glitter decorative article obtained by the manufacturing method of the present invention.

FIG. 3 is a cross-sectional view showing a state in which the glittering decorative sheet of the present invention is being heated.

FIG. 4 is a cross-sectional view showing a state after heating the glittering decorative sheet of the present invention.

FIG. 5 is a sectional view showing a state in which the glittering decorative sheet of the present invention is placed along a vacuum forming die.

FIG. 6 is a cross-sectional view showing one step of the method for manufacturing a glittering decorative article of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base sheet 2 Adhesive layer 3 Bright layer 4 Surface protective layer 5 Bright decorative sheet 6 Molding resin 8 Upper heat source 9 Lower heat source 10 Clamp 11 Vacuum forming die 12 Vacuum suction hole 13 Slide device 14 Injection molding die

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) B44C 5/08 B44C 5/08 B B44F 1/02 B44F 1/02 // B29L 31:34 B29L 31:34 31:58 31:58 F-term (Reference) 4F100 AB10B AB13B AB16B AB17B AB21B AB25B AK07 AK15G AK15J AK22G AK22J AK25 AK51 AK51G AK74 AL01G AR00A AR00B BA02 BA03 CB00 EH66B GB33 GB48 HB00 AJB02 AB JA02 ADB JB19 JF05 JL02 JM05 JN22 JN25 JN33

Claims (5)

[Claims] 1. A method for measuring the specular gloss Gs (60 °) after thermoforming of a glittering decorative sheet having at least a glittering layer formed on a thermoformable base sheet, as defined in JIS-Z8741. 3. The glittering decorative sheet according to claim 1, wherein 43% or more before the thermoforming is maintained. 2. The glittering decorative sheet according to claim 1, wherein the condition of the thermoforming is such that after the glittering decorative sheet is softened by heating, it is deformed by vacuum or pressure forming within 5 seconds. . 3. The glittering layer is a vapor deposited layer formed by using any one of aluminum, chromium, indium, tin, nickel, gold, silver, copper, and platinum, or an alloy thereof. 3. The glittering decorative sheet according to any one of 1 to 2. 4. The glittering decorative sheet according to claim 1, which is softened by heating in advance, deformed by vacuum or pressurized air, set in an injection molding die, and closed. A method of manufacturing a glittering decorative article, comprising injecting a molding resin into a cavity and integrally bonding a glittering decorative sheet and an injection molded article. 5. The glittering decorative sheet according to claim 1, which is set in a mold for injection molding, softened by heating in the mold for injection molding, and then deformed by vacuum or compressed air. A molding resin is injected into the cavity, and the glittering decorative sheet and the injection-molded product are integrally bonded to each other.