JP2002347105A - Method for manufacturing decorated molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorated molded article which can provide a molded article excellent in appearance by using fiber- reinforced thermoplastic resin sheets. SOLUTION: A laminated layer body W is formed of a decorated sheet S which is made by applying a decorating treatment to the thermoplastic resin base sheet and the fiber reinforced thermoplastic resin sheet T, and the laminated layer body W, after being disposed between a pair of molding dies 11, 12 for being heated and softened, is heated and pressurized by engaging the molding dies 11, 12 to mold. A decorated molded article wherein a decorated sheet S is integrally layered on the fiber-reinforced thermoplastic resin sheet T is obtained by opening the molding dies 11, 12 after the laminated body being cooled and cured. In this way, a decoration can be made on the surface of the fiber reinforced thermoplastic resin molding, so that the application range can be expanded to portions where the fiber reinforced thermoplastic resin sheet can not be employed heretofore because of an appearance reason.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative molded article using a fiber-reinforced thermoplastic resin sheet.

[0002]

2. Description of the Related Art Fiber-reinforced thermoplastic resin sheets (also referred to as stampable sheets) have been widely known, and are often used in various applications such as automobile parts and home electric appliance parts. This fiber reinforced thermoplastic resin sheet is a fiber reinforced resin (a so-called FR) using a thermosetting resin.
Compared with P), since there is no chemical reaction during molding, a molding cycle similar to sheet metal pressing is possible, and since it has high strength and is also resistant to chemicals, it can be used for various parts instead of metal. (See, for example, JP-A-8-230114 and JP-A-9-38968).

[0003] In the case of manufacturing a decorative molded article using this fiber-reinforced thermoplastic resin sheet, a decorative sheet obtained by performing pattern printing on the thermoplastic resin sheet is placed between a pair of molds,
Next, the fiber-reinforced thermoplastic resin sheet is placed in a heated and molten state, and then the molding die is engaged and pressed to form the fiber-reinforced thermoplastic resin sheet into a desired shape and to decorate the surface of the molded product. A method of laminating and integrating the sheets is adopted (for example, see JP-A-4-25420, JP-B-7-39102, etc.).

[0004]

The fiber-reinforced thermoplastic resin sheet used in the decorative molded article described in the prior art has a high glass fiber content in order to realize high strength. For this reason, the obtained decorative molded article has a problem that the pattern of the glass fiber appears, and also has a problem that the appearance is not good because the color is limited to a color in which unevenness of the fiber and the matrix resin is not conspicuous. Its use has been limited to parts that are not directly visible, such as the engine parts of automobiles and the skeleton parts of home appliances.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to obtain a molded article having an excellent appearance while using a fiber-reinforced thermoplastic resin sheet. It is an object of the present invention to provide a method of manufacturing a decorative molded product that can be performed.

[0006]

In order to achieve the above object, a method for producing a decorative molded article according to the present invention comprises a decorative sheet obtained by performing a decorative treatment on a thermoplastic resin base sheet and a fiber-reinforced thermoplastic resin. A laminate is formed with a resin sheet, and the laminate softened by heating is placed between a pair of molds, and the mold is engaged to form a laminate by heating and pressing. Then, after cooling and solidifying, the mold is opened to obtain a decorative molded product in which the decorative sheet is laminated and integrated on the fiber-reinforced thermoplastic resin sheet.

In the above method of manufacturing a decorative molded product, the laminate is placed between a pair of molding dies to be softened by heating, and then the laminate is subjected to the surface of one of the molding dies. It is also possible to perform vacuum forming on the upper surface, and then engage the mold.

[0008]

Embodiments of the present invention will be described below in detail.

The decorative sheet is formed by performing a decorative treatment on a thermoplastic resin base sheet. Since it is desirable that this decorative sheet conceals the defects on the surface of the fiber-reinforced thermoplastic resin sheet and can transfer the surface smoothness of the mold or the unevenness for decoration, it is better than the matrix resin of the fiber-reinforced thermoplastic resin sheet described later. It is desirable that the fluidity during preheating be low.

Examples of such a thermoplastic resin base sheet include thermoplastic resins such as acrylic resins, polyester resins, polyolefin resins, vinyl chloride resins, polyolefin resins, polycarbonate resins, and fluorine resins, and copolymers and mixtures thereof. The used single-layer sheet or a laminated sheet of different single-layer sheets among these single-layer sheets can be used.

[0011] Representative examples of the form of the laminated sheet are listed below. (1) On the front side (opposite to the fiber reinforced thermoplastic resin sheet side), use a fluororesin having excellent surface properties such as weather resistance, chemical resistance, heat resistance, etc., and on the back side (fiber reinforced thermoplastic resin sheet side). ), A resin which is inferior to a fluororesin in terms of surface physical properties but has excellent adhesion to other layers is used. As the resin having excellent adhesiveness, a resin of the same kind as the matrix resin of the fiber-reinforced thermoplastic resin sheet or a resin having an adhesiveness to the matrix resin is preferable. When the matrix resin is a polyolefin resin, a polyolefin resin is used as the easily adhesive resin. When the matrix resin is an ABS resin, an acrylic resin, or polystyrene, an acrylic resin is used as the easily adhesive resin. (2) A biaxially stretched sheet of polyethylene terephthalate or polyethylene naphthalate having excellent mirror smoothness, scratch resistance and heat resistance is used on the front side, and a polyolefin resin or polyvinyl chloride sheet having excellent moldability is used on the back side. Used.

Specific examples of the acrylic resin include polymethyl (meth) acrylate, polyethyl (meth) acrylate, polybutyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymer, and ethyl (meth) acrylate. -Butyl (meth)
Acrylate copolymer, methyl (meth) acrylate-
Acrylic resins such as ethylene copolymers and methyl (meth) acrylate-styrene copolymers (however, (meth) acrylate means acrylate or methacrylate) are exemplified.

Specific examples of the above polyester resin include:
Examples include polyethylene terephthalate, polybutylene terephthalate, ethylene-terephthalate-isophthalate copolymer, polyethylene naphthalate, polyester-based thermoplastic elastomer, and amorphous polyester. Examples of the polyester-based thermoplastic elastomer include an aromatic polyester having a high crystallinity and a high melting point in a hard segment, and a block polymer using an amorphous polyether having a glass transition temperature of -70 ° C or less in a soft segment. For example, polybutylene terephthalate is used for the aromatic polyester having a high melting point, and polytetramethylene glycol is used for the amorphous polyether. In addition, typical examples of the amorphous polyester include an ethylene glycol-1,4-cyclohexanedimethanol-terephthalic acid copolymer.

Examples of the polyolefin resin include polyethylene (high density, medium density, or low density), polypropylene (isotactic or syndiotactic), polybutene, ethylene-propylene copolymer, ethylene-propylene-butene. Copolymers, olefin-based thermoplastic elastomers and the like can be mentioned. Examples of the olefin-based thermoplastic elastomer include a hard segment composed of a crystalline polyolefin resin as exemplified above, ethylene-propylene rubber, ethylene-propylene-diene rubber, atactic polypropylene, styrene-butadiene rubber, hydrogenated styrene-butadiene rubber, and the like. A mixture of a soft segment made of an elastomer and a soft segment is used. The mixing ratio of the hard segment and the soft segment is [soft segment / hard segment] = 5 /
It is about 95 to 40/60 (mass ratio). If necessary, the elastomer component is crosslinked with a known crosslinking agent such as sulfur or hydrogen peroxide.

Examples of the fluororesin include polyvinyl fluoride, polyvinylidene fluoride, ethylene-tetrafluoroethylene copolymer, tetrafluoroethylene-6-fluoropropylene copolymer, ethylene-chlorotrifluoroethylene copolymer. And the like. Alternatively, by mixing about 30 to 70% by mass of the acrylic resin in these fluorine resins,
While maintaining the weather resistance of the fluororesin, easy adhesion to other layers such as a fiber-reinforced thermoplastic resin sheet and a pattern ink layer can be provided.

The thickness (the total thickness in the case of a laminated sheet) of the thermoplastic resin base sheet is about 20 to 200 μm. To improve the light resistance (weather) of the thermoplastic resin substrate sheet, an ultraviolet absorber and a light stabilizer are added. Among them, as the ultraviolet absorber, for example, the following (1)
Compounds such as (5) to (5) can be used.

(1) Benzophenones: 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxy-benzophenone, 2-hydroxy-4-n-octoxybenzophenone, 2-hydroxy-4-methoxy-benzophenone-5 Sulfonic acid. (2) benzotriazole type; 2- (2′-hydroxy-5′-methylphenyl) benzotriazole,
(2′-hydroxy-3′-t-butyl-5′-methylphenyl) -5-chlorobenzotriazole, 2-
(2′-hydroxy-3 ′, 5′-di-tert-butylphenyl) -5-chlorobenzotriazole, 2- (2′-
Hydroxy-3 ', 5'-dicumylphenyl) phenylbenzotriazole, 2- (2'-hydroxy-3'-
Dodecyl-5'-methylphenyl) benzotriazole, 2,2'-methylenebis [4- (1,1,3,3-
Tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol]. (3) Acrylate; ethyl-2-cyano-3,3 ′
-Diphenyl acrylate, 2-ethylhexyl-2-
Cyano-3,3'-diphenyl acrylate. (4) salicylate; phenyl salicylate, 4-t
-Butylphenyl salicylate. (5) Oxalinides; 2-ethoxy-2'-ethyloxalic acid bisanilide, 2-ethoxyxin-5
t-Butyl-2'-ethyloxalic acid vinylisanilide.

The ratio of applying these ultraviolet absorbers is as follows:
Preferably, 0.1 to the resin content of the layer to be added.
２2% by mass. If it is less than 0.1% by mass, the effect of addition is poor, and if it exceeds 2% by mass, the effect is not improved.

As the light stabilizer, for example, a hindered amine radical scavenger can be used. As the hindered amine radical scavenger, for example, bis- (2,2,6,6-tetramethyl-4-piparidinyl) sebacate, bis- (N-methyl, 2,2,6,
6, -tetramethyl-4-piperodinyl) sebacate,
[Dimethyl succinate-16 (2-hydroxyethyl)-
4-hydroxy-2,2,6,6-tetramethylpiperidine] condensate, poly {[6- (1,1,3,3-tetramethylbutyl) imino] -1,3,5-triazine-
2,4-diyl [(2,2,6,6-tetramethyl-4
-Piperidyl) imino] hexamethylene [(2,2,
6,6-tetramethyl-4-piperidyl) iminol]}.

The ratio of adding these light stabilizers is preferably 0.1 to 2 with respect to the resin content of the layer to be added.
% By mass. If it is less than 0.1% by mass, the effect of addition is poor, and if it exceeds 2% by mass, the effect is not improved.

The ultraviolet absorber and the light stabilizer are effective even when used alone, but it is not clear why they are used in combination, but the effects are synergistically improved. Is desirable. If the ultraviolet absorber and the light stabilizer are simply mixed, bleeding during use is inevitable. Therefore, instead of the hindered amine-based light stabilizer, 4- (meth) acryloyloxy-2,2,2 is used. 6,
6-tetramethylpiperidine, 4- (meth) acryloyloxy-1,2,2,6,6-pentamethylpiperidine, 4- (meth) acrylolyloxy-1-propyl-
2,2,6,6-tetramethylpiperidine, or 4-
(Meth) acryloyloxy-1-butyl-2,2,2
Compounds having a (meth) acryloyloxy group such as 6,6-tetramethylpiperidine, or 4-crotonoyloxy-2,2,6,6-tetramethylpiperidine, or 4-crotonoyloxy-1-propyl-2 , 2,
It is desirable to prevent bleeding by using a resin obtained by graft copolymerizing a compound having a crotonoyloxy group such as 6,6-tetramethylpiperidine.

As a specific example of the decoration treatment applied to the thermoplastic resin base sheet, a known decoration treatment such as addition of a coloring agent to the base sheet itself and formation of a decoration layer by forming a picture ink layer can be used. These decoration processes can be used alone or in combination.

FIGS. 1A to 1E show a decorative sheet obtained by performing a decoration treatment on a thermoplastic resin base sheet. Among these, the decorative sheet S of FIG.
1B, a decorative sheet S in FIG. 1B in which a pattern ink layer 2 is formed on the back side of the base sheet 1;
The decorative sheet S in FIG. 1 (C) is obtained by adding a colorant to the base sheet 1 and forming a pattern ink layer 2 on the front side. The decorative sheet S shown in FIG. 1 (D) is prepared by adding a coloring agent and forming a pattern ink layer 2 on the front side as a backing base sheet 3, and using this and the front base sheet 4 as an adhesive layer 5. The decorative sheet S shown in FIG. 1E has a pattern ink layer 2 on the back side of the base sheet 1.
Is formed, a surface coating film 6 is formed on the front side, and an adhesive layer 7 is further provided so as to cover the picture ink layer 2 on the back side.

The decoration treatment applied to the thermoplastic resin base sheet is preferably performed on the back side of the base sheet to improve the durability such as abrasion resistance, water resistance and weather resistance of the decoration processing by the base sheet. It is preferable because it can be performed.

The pattern ink layer is formed, for example, by gravure printing,
Known printing methods such as offset printing, silk screen printing, ink jet printing, transfer printing from a transfer sheet,
Alternatively, it can be formed by hand drawing or the like. Also,
In the case of full solid pattern, gravure coat, roll coat,
It can be formed by a known coating method such as spray coating. Inks that form the picture ink layer include chlorinated polyolefins such as chlorinated polyethylene and chlorinated polypropylene, polyester resins, urethane resins, acrylic resins, vinyl acetate resins, vinyl chloride-vinyl acetate copolymers, and resins such as cellulose resins. Is used as a binder, and a colorant and other additives are appropriately added thereto.

Examples of the coloring agent include inorganic pigments such as titanium white, zinc white, carbon black, iron black, red iron oxide, chrome vermilion, ultramarine, cobalt blue, graphite, titanium yellow, phthalocyanine blue, and indus Organic pigments (including dyes) such as Renblue, Isoindolinone Yellow, Benzidine Yellow, Quinacridone Red, Polyazo Red, Perylene Red, and Aniline Black; or metallic pigments consisting of scale-like foil pieces such as aluminum and brass, titanium dioxide Pearlescent pigments (pearl pigments) made of scale-like foil pieces such as coated mica and basic lead carbonate are used.

The pattern of the pattern ink layer includes, for example, wood grain, stone grain, cloth grain, sand grain, tiled pattern, brickwork pattern, leather pattern, geometric pattern, letters, symbols, solid color, and the like.
One or more of these may be used in combination according to the application.

Further, a metal thin film layer may be provided as a decoration process. This metal thin film layer is made of aluminum, chromium,
Using a metal such as gold, silver or copper, a film is formed by a method such as vacuum evaporation or sputtering. The metal thin film layer may be provided on the entire surface, or may be provided partially in a pattern.

When a colorant is added to the base sheet itself, a colorant selected from the same ones listed as the colorants for the picture ink is added to the base sheet as appropriate, alone or in combination. By doing so, desired coloring is performed.

In addition, if necessary, the decorative sheet is provided with a layer for expressing functions such as a surface coating film, a cushion layer made of a foamed resin, a magnetic layer, a phosphor layer, and a conductor layer. Each of these layers can be sandwiched between laminated resin sheets as needed.

The adhesive layer is not always necessary, but when the molded article is used for a long period of time, the adhesiveness may be insufficient only by heat fusion. In such a case, the adhesive layer is provided. The adhesive is used for adhesion between the decorative sheet and the thermoplastic resin base sheet, adhesion between layers of the decorative sheet, and the like. Examples of the adhesive include thermoplastic resins such as polyvinyl acetate, ethylene-vinyl acetate copolymer, vinyl chloride-vinyl acetate copolymer, acrylic resin, thermoplastic polyester resin, thermoplastic urethane resin, polyamide resin, and chlorinated polypropylene. Alternatively, a heat-sensitive adhesive composed of a thermosetting resin such as a two-component curable urethane resin, an epoxy resin, a phenol resin, a melamine resin, and a diallyl phthalate resin is preferable.

The fiber-reinforced thermoplastic resin sheet serving as the base material of the decorative molded article is composed of a composite of a matrix resin composed of a thermoplastic resin and reinforcing fibers. Typically, a material in which glass fibers are dispersed in polypropylene resin is often used. However, in the present invention, the material is not particularly limited, and glass fibers, quartz fibers, carbon fibers, and boron fibers are used as reinforcing fibers. And inorganic fibers such as potassium titanate fibers, or organic fibers such as polyamide fibers, aramid fibers, and polyester fibers. The fiber length of these reinforcing fibers is about 5 to 30 mm from the viewpoint of the balance between the reinforcing effect and the moldability, and the fiber diameter is about 5 to 30 μm. The amount of reinforcing fiber added is (fiber / matrix resin) = 20/80
Approximately 70/30 (mass ratio), and the surface of the fiber may be subjected to a silane coupling treatment, if necessary. As the silane coupling agent, a vinyl silane type, an amino silane type, an epoxy silane type or the like is used. Also,
For the matrix resin, consider the strength and adhesion with the decorative sheet from various thermoplastic resins such as polyester resin, polycarbonate resin, acrylic resin, ABS resin, polystyrene, polyvinyl chloride and polyolefin resin. You can choose. Granular resins can also be used as the matrix resin. In that case, the particle size should be 50 in view of the suitability for dispersion in the reinforcing fiber.
It is preferable to set it to about 2000 μm. Also, the method for dispersing the reinforcing fibers is not particularly limited, such as a papermaking method, a laminating method, and a dry dispersion method.

In the method for producing a decorative molded article of the present invention, a decorative sheet and a fiber-reinforced thermoplastic resin sheet are preliminarily laminated to form a blank, which is preheated and then integrally molded to give a pattern or the like. A decorative molded article having a good appearance is obtained.

Then, by integrally forming the decorative sheet during the production of the fiber-reinforced thermoplastic resin sheet, the step of bonding the decorative sheet to the fiber-reinforced thermoplastic resin sheet can be omitted. That is, in the production of a fiber-reinforced thermoplastic resin sheet, there is a step of applying pressure while heating in both the dispersion method and the laminating method, and in this step, thermocompression bonding is performed, or an adhesive is used depending on the demand for adhesion strength and durability. To perform lamination. As the adhesive, a so-called heat-sensitive adhesive which is solid at room temperature and melts or undergoes a cross-linking polymerization reaction when heated can be used, but it is necessary to select an adhesive which does not hinder molding during stamping molding. When the decorative sheet is not laminated during the production of the fiber-reinforced thermoplastic resin sheet, the decorative sheet can be laminated on the fiber-reinforced thermoplastic resin sheet while applying an adhesive.

The molding temperature is appropriately set according to the type of the fiber-reinforced thermoplastic resin sheet to be molded, the molded shape, and the type of the decorative sheet.
at softening temperature or higher, preferably melting point (or melting temperature) or higher. However, the temperature is controlled so as not to cause decomposition or deterioration of the resin. Usually, about 120 to 230 ° C, molding pressure is 3 to
50 kg / cm ² or so, the molding time is about 1 to 10 minutes.

Heat-press molding (hot press) is performed, for example, as shown in FIG.
The laminated body W of the decorative sheet S and the fiber-reinforced thermoplastic resin sheet T is placed between a pair of molding dies including the female mold 11 and the male mold 12 using a known heat press as shown in FIG. Do it.

In the present invention, the laminate W is heated and softened before the laminate W is heated and pressed to form the same.
For this preheating, as shown in FIG. 3, it is preferable to use an infrared radiation type heating plate 20 using a heating wire, a ceramic heater or the like. In this way, by laminating the laminate W placed between the molds by heating and softening, the followability of the molded shape of the laminate W is further improved, and tearing and wrinkling at the time of molding can be prevented. Even when the shape is a deep drawn shape, it can follow the shape satisfactorily without wrinkles or tears.

In the embodiment shown in FIGS. 2 and 3, the unheated laminate is first placed between the molds, and then the hot plate is inserted into the mold to soften the laminate by heating. . This embodiment is an excellent manufacturing method in terms of preventing deformation of the laminate W when the decorative sheet is conveyed into the mold and preventing displacement of the laminate W from the mold. However, in terms of shortening the molding cycle and improving molding efficiency (not shown)
It is more preferable that the laminate W is heated and softened by a hot plate or the like while the laminate W is being conveyed between the molds, and then the heat-softened laminate is placed between the molds.

After the laminate W is softened by heating, it is preferable that the laminate W is vacuum-formed on the surface of one of the molds, and then the mold is engaged. In this case, vacuum forming on the surface of one of the molds may be performed, for example, by using a vacuum pump through a vacuum suction hole 11a (or groove) formed in the female mold 11, as shown in FIG.

Then, from the state shown in FIG.
The female mold 11 and the male mold 12 are engaged by operating the laminate 14, and the laminated body W is formed by heating and pressing. Then, after cooling and solidifying, the female mold 11 and the male mold 12 are opened to obtain a decorative molded article in which the decorative sheet is laminated and integrated on the fiber-reinforced thermoplastic resin sheet.

[0041]

Next, an embodiment of the present invention will be described.

(1) Preparation of Fiber-Reinforced Thermoplastic Resin Sheet First, a dispersion having the following composition (the number indicates the blending mass ratio) was applied to a paper machine, suctioned and defoamed, and further air-dried to obtain a rice basis weight of 600 g / g. An m ² fiber reinforced thermoplastic resin sheet was prepared.

[Composition of Dispersion] Matrix resin: polypropylene particles 20.625 reinforcing fiber 1: glass fiber chopped strand (A) 9.375 reinforcing fiber 2: glass fiber chopped strand (B) 7.500 Dispersion medium: dodecylbenzene Sodium sulfonate aqueous solution 10,000

In the above composition, the polypropylene particles have an average particle size of 500 μm and a melting point of 155 ° C.
The glass fiber chopped strand (A), which is the reinforcing fiber 1, has a fiber length of 13 mm, a fiber diameter of 17 μm, an aminosilane coupling agent treatment of 0.005% by mass, a polyethylene oxide convergent agent treatment of 0.05% by mass, and a converging number of 5
000 pieces / bundle. The glass fiber chopped strand (B) as the reinforcing fiber 2 has a fiber length of 13 m.
m, fiber diameter 23 μm, aminosilane coupling agent 0.
005% by mass, polyethylene oxide-based sizing agent 0.05% by mass, convergence number: 5000 lines / bundle).

(2) Preparation of Decorative Sheet Titanium white and a valve were added to a polypropylene thermoplastic elastomer comprising a mixture of 75 parts by mass of a hard segment made of isotactic polypropylene and 25 parts by mass of a soft segment made of atactic polypropylene. A yellowish-brown back substrate sheet (thickness: 200 μm) was prepared by adding a pattern and a coloring agent mainly composed of graphite.

Then, a corona discharge treatment was applied to the back surface of the back substrate sheet, and then the polyester polyol 1
A two-part curable urethane resin consisting of 00 parts by mass and 6 parts by mass of 1,6-hexamethylene diisocyanate is 4 g / m 2.
² (at the time of drying) was applied to form an easily adhesive primer layer.
On the easy-adhesion primer layer, a wood grain pattern ink layer was formed as a decorative layer by gravure printing. The pattern ink uses a mixture of a vinyl chloride-vinyl acetate copolymer and an acrylic resin at a mass ratio of 5: 5 as a binder resin, and a colorant mainly composed of carbon black (black ink) and a red stalk. Was.

Next, a vinyl chloride-vinyl acetate copolymer and an acrylic resin were used as an adhesive layer on the pattern ink layer ((vinyl chloride-vinyl acetate copolymer) / (acrylic resin) = 2/8 mass). A transparent adhesive layer mixed at a ratio was formed with a gravure roll coater to a thickness of 4 μm (when dried).

Next, 0.8 parts by mass of a benzotriazole-based ultraviolet absorber and 0.4 parts by mass of a hindered amine-based radical scavenger are added to polymethyl methacrylate.
A 100 μm-thick surface substrate sheet was heat-sealed, and FIG.
A decorative sheet having a sectional structure as shown in (D) was obtained.

(3) Preparation of laminated body of decorative sheet and fiber-reinforced thermoplastic resin sheet The fiber-reinforced thermoplastic resin sheet obtained in (1) and the decorative sheet obtained in (2) above were decorated. The decorative sheet is overlaid so that the base sheet side faces the fiber-reinforced thermoplastic resin sheet, and heated and heated to 170 ° C, passed between rotating pressure rollers of a rotary-type roll heat press, and pressed and laminated. did. As the pressure roller, a roller composed of a metal roll having a surface temperature of 60 ° C. with chromium plating and a pressure drum roller coated with silicon rubber around the metal core was used. Was in contact with the side of the topsheet.

(4) Heat-Pressure Molding of the Laminate As shown in FIG. 2, the laminate obtained in the above (3) was inserted between a pair of molding dies composed of the female mold 11 and the male mold 12. At this time, the laminate was placed so that the surface substrate sheet side of the laminate faced the surface side of the female mold 11. The female mold 11 and the male mold 12 were made of carbon steel. After the mounting, as shown in FIG.
The laminate W was brought into close contact with the surface of the female mold 11 by heating to ° C. and suctioning through the vacuum suction holes 11 a of the female mold 11.

Subsequently, the female mold 11 and the male mold 12 were engaged with each other, and the laminate W was heated and pressed to perform molding. The molding conditions in the pressurization step are mold temperature 210 ° C., pressure 10 kg / c.
m ² , pressurization time is 1 minute, and molding conditions in the cooling process are as follows:
The mold temperature was 60 ° C., the pressure was 10 kg / cm ² , and the pressing time was 3 minutes. After the molding, the female mold 11 and the male mold 12 were opened, and the molded product was taken out. As a result, the decorative sheet was laminated and integrated on the surface, and a decorative molded product molded into a desired shape was obtained.

Although the embodiments and examples of the present invention have been described in detail above, the method of manufacturing a decorative molded product according to the present invention is not limited to the above-described embodiments and examples. Naturally, various changes can be made without departing from the spirit of the present invention.

[0053]

As described above, according to the method for producing a decorative molded product of the present invention, it is possible to decorate the surface of a fiber-reinforced thermoplastic resin molded product, and conventionally, emphasis is placed on aesthetics. Therefore, the application range can be expanded to a portion where the fiber reinforced thermoplastic resin sheet cannot be used.

Further, by selecting a resin to be used for the surface of the decorative sheet, it is possible to impart properties such as weather resistance, chemical resistance and coating suitability to the molded product.

Further, it is not always necessary to cover the entire surface exposed at the time of use with the decorative sheet, and if the texture of the fiber-reinforced thermoplastic resin sheet is sufficient, a transparent pattern in which a pattern, a precautionary statement, etc. are added to a part of the sheet. A film may be used, or a specification in which a decorative sheet is attached to only a part of the fiber-reinforced thermoplastic resin sheet is also possible.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a decorative sheet obtained by performing a decoration process on a thermoplastic resin base sheet.

FIG. 2 is a schematic configuration diagram showing an example of a hot press used in the production method of the present invention.

FIG. 3 is a schematic configuration diagram showing a state in which a hot plate is used to preheat a laminate of a decorative sheet and a fiber-reinforced thermoplastic resin sheet placed between molding dies of a hot press machine.

[Explanation of symbols]

 S Decorative sheet T Fiber reinforced thermoplastic resin sheet W Laminate 1 Base sheet 2 Picture ink layer 3 Back base sheet 4 Surface base sheet 5 Adhesive layer 6 Surface coating 7 Adhesive layer 11 Female mold 11a Hole 12 Male type 13,14 Ram 20 Hot plate

 ──────────────────────────────────────────────────の Continued on the front page F-term (reference) 4F100 AG00B AK01B AK07A AK07B AK15G AK15J AK22G AK22J AK25G AL01G AL05G AL09A AT00A BA02 CB00 DG01B DG03B DH00B EC032 EC051 EJ202 J03 MB01 J03 ECB JB32J01B32J03B03J01B32J01 MG05 MG11 MH07 MJ23

Claims (2)

[Claims] 1. A laminate of a decorative sheet obtained by subjecting a thermoplastic resin base sheet to a decorative treatment and a fiber-reinforced thermoplastic resin sheet is formed, and the heat-softened laminate is formed into a pair of moldings. While being placed between the molds, the laminate is heated and pressurized to form a molded body by being engaged with the mold, cooled and solidified, and then opened by opening the mold, so that the laminate is placed on the fiber-reinforced thermoplastic resin sheet. A method for producing a decorative molded product, comprising obtaining a decorative molded product in which decorative sheets are laminated and integrated. 2. The method of manufacturing a decorative molded product according to claim 1, wherein the laminate is placed between a pair of molds and softened by heating, and then the laminate is formed on one of the molds. A method for producing a decorative molded product, comprising vacuum forming on a surface of a mold, and thereafter engaging the mold.