JP2003071961A - Sheet material substituted for coating, molded object using the same, and method for manufacturing them - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sheet material substituted for coating capable of suppressing the lowering of a quality feeling due to an in-mold molding method, a molded object using the same, and a method for manufacturing them. SOLUTION: The sheet material 10 substituted for coating is constituted of an adhesive layer 11 comprising a synthetic resin, a color coating film 12 comprising a synthetic resin paint and the protective film 14 laminated on the surface of a transparent film 13. The molded object is obtained by laminating the adhesive layer 11, the color coating film 14 and the transparent film 13 on the surface of a molded substrate made of a synthetic resin having a predetermined shape by the in-mold molding method using the sheet material substituted for coating. The protective film 14, the color coating film 12 and the transparent film 13 have an elongation at breake of 50-250% so as to be capable of being uniformly laminated on the surface of the molded substrate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a synthetic resin molded body obtained by an in-mold molding method, for example, a surface of interior parts, exterior parts, etc. such as automobile bumpers, garnishes, trims, instrument panels, door trims, etc. A sheet material as an alternative to coating for providing a colored coating capable of improving durability and imparting a glossy texture such as solid, metallic and pearl tones, a molded article using the same, and a method for producing the same Is.

[0002]

2. Description of the Related Art Generally, molded articles such as the above-mentioned automobile interior parts and exterior parts are formed of a synthetic resin base material.
It is composed of a colored film formed on the surface thereof and a transparent film laminated on the surface of the colored film. The molding substrate is molded into a predetermined shape by an injection molding method or the like. The colored coating film is applied by applying a colored coating material to the surface of the molding substrate using a spray gun or the like, and baking and drying. The transparent film is formed by drying the colored coating and then applying a clear coating on the surface thereof in the same manner as the colored coating.

However, in this case, the molding operation of the molding substrate,
There has been a problem that a plurality of work steps are required to obtain a molded product such as a coating work for applying a colored paint and a clear paint on the surface, and the manufacturing work is complicated and it is difficult to rationalize. In addition, there is a problem that chemical substances such as organic solvents contained in the colored paint and the clear paint are dissipated in the air.

In order to solve such a problem, in recent years, when a molded substrate is molded into a predetermined shape, a colored film is formed on the surface of the coating substitute sheet material to obtain a molded product. Is used as an alternative to coating. This coating substitute sheet material includes a transparent film made of a transparent film and a colored film formed by coating a polyester-based or polyacrylic-based coating on the back surface of the transparent film, and a resin film on the back surface of the colored film. It is configured by laminating the adhesive layers. The transparent film is mainly made of thermoplastic olefins, acrylics,
It is formed of a resin sheet such as a fluorine-based resin.

When the in-mold molding method is carried out, the coating substitute sheet material is previously arranged in the cavity formed inside in the pair of molds forming the molding substrate. After that, the synthetic resin that is heated and melted to form the molding substrate is injected from the gate provided on the adhesive layer side. Then, the adhesive sheet is thermally fused to the surface of the molding substrate while the coating substitute sheet material is thermally deformed according to the shape of the inner surface of the mold. Then, the mold is opened after cooling to obtain a molded product including a molding substrate, a colored coating formed on the surface of the molding substrate, and a transparent film laminated on the surface of the colored coating.

[0006]

However, when the in-mold molding method is carried out using the above-mentioned coating substitute sheet material, the transparent film made of the transparent film does not sufficiently extend or breaks upon thermal deformation, etc. May occur. In such a case, wrinkles, cracks, etc. occur on the surface of the molded body formed by the transparent film, or the molding base material is not molded into a predetermined shape, so that the surface texture of the molded body deteriorates. There was a problem.

The present invention has been made by paying attention to the problems existing in the prior art. It is an object of the present invention to provide a sheet material for coating substitute, which can suppress deterioration of texture due to the in-mold molding method, a molded body using the same, and a manufacturing method thereof.

[0008]

In order to achieve the above object, the invention of a sheet material for coating substitution according to claim 1 is
Substitution of coating used as an alternative to coating, which is used in the in-mold molding method in which a colored film is formed on the surface of a molding base to obtain a molded body when molding a molding base made of synthetic resin into a predetermined shape. A sheet material for a vehicle, comprising a colored film formed of a synthetic resin and a protective film formed of a thermoplastic resin laminated on the surface of the colored film, wherein the colored film and the protective film are JIS K 6
The elongation at break defined by No. 251 is 50 to 250%.

The invention of a sheet material for coating substitution according to a second aspect is the invention according to the first aspect, wherein a transparent film formed of a transparent synthetic resin is laminated on the surface of the colored film,
The transparent film is disposed between the colored film and the protective film, and the transparent film is used for molding the molded product at the time of molding.
The elongation at break specified by SK 6251 is 50 to 25.
It is characterized by being 0%.

The invention of a sheet material for coating substitution according to claim 3 is characterized in that, in the invention according to claim 1 or 2, an adhesive layer is provided on the back surface of the colored coating film. .

According to a fourth aspect of the present invention, in the method for producing a coating substitute sheet material according to the second or third aspect, a protective film made of a thermoplastic resin is formed, and a back surface thereof is made of a synthetic resin. After the transparent film is formed, a colored film made of synthetic resin is laminated on the back surface of the transparent film.

The invention of the molded article according to claim 5 is obtained by an in-mold molding method using the coating substitute sheet material according to claim 2 or 3, and has a predetermined shape made of synthetic resin. It is characterized by comprising a molding base material, a colored film adhered to the surface of the molding base material, and a transparent film formed on the surface of the coloring film.

According to a sixth aspect of the present invention, there is provided a method of manufacturing a molded article, wherein the coating substitute sheet material according to the second or third aspect is arranged in a cavity of a pair of molds, and the mold is placed in both molds. In order to form the molding base material by injecting the heat-melted synthetic resin material that forms the molding base material from the gate provided on the side of the colored film of the coating substitute sheet material, and cooling both molds. Almost at the same time, the colored film is heat-fused on the surface of the molding substrate to integrate the molding substrate, the colored film and the transparent film, and in this state, both molds are opened to remove the protective film from the surface of the transparent film. It is characterized by that.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below with reference to the drawings. As shown in FIG. 2B, a molded body having a predetermined shape, which is used as an interior part and an exterior part of an automobile such as a garnish, a trim, an instrument panel, a door trim, a bumper, etc. The decorative layer 22 attached to the upper surface of the base material 21. The molding substrate 21 is formed of a polyolefin resin such as polyethylene or polypropylene, or a synthetic resin such as acrylonitrile-butadiene-styrene copolymer resin (ABS resin). The decorative layer 22 is applied to the surface of the adhesive layer 11, which is laminated on the surface of the molding substrate 21, the colored film 12 formed of the colored paint on the surface of the adhesive layer 11, and the surface of the colored film 12.
It is composed of a transparent film 13 made of a transparent paint for protecting this. The surface of the colored coating film 12 protected by the transparent film 13 is smooth.

A molded body is composed of the molding base material 21 and the decorative layer 22. The surface of the molded body is colored by the colored coating 12 of the decorative layer 22. The transparent film 13 increases the depth of the color tone of the colored film 12, and the smooth surface of the colored film 12 over the transparent film 13 vividly captures a landscape and the like, thereby improving the sharpness of the transparent film 13. A glossy feeling is imparted by the luster and the texture of the molded body is improved.

The decorative layer 22 of the molded body is formed by the molded base material 21.
Is formed by using a sheet material for coating substitution as a means for coating the surface of the sheet. Therefore, the coating substitute sheet material will be described. In addition, hereinafter, the coating substitute sheet material is simply referred to as a sheet material.

As shown in FIG. 1, the sheet material 10 is laminated on the surface of the transparent film 13 and a decorative layer 22 composed of the adhesive layer 11, the colored coating 12 and the transparent film 13, and a protective film 14 for protecting the same. It consists of and.

The adhesive layer 11 is heat-bonded to the molding base material 21 to bond the colored coating 12, the transparent film 13 and the protective film 14 to the molding base material 21, thereby forming the molding base material 21 and the coloring coating 12. And the transparent film 13 are integrated. Therefore, as the material of the adhesive layer 11, it is preferable to use a synthetic resin that is easily heat-sealed to the molding base 21. Examples of such synthetic resins include polyethylene-based resins, polypropylene-based resins, polyurethane-based resins, polystyrene-based resins, polyacrylic-based resins, polyolefin-based or polystyrene-based thermoplastic elastomers, and the like.

The colored coating film 12 is formed of a colored coating material containing a pigment, a synthetic resin that binds the pigment, and a solvent that dissolves these. It is preferable to use an opaque colorant for this pigment so that it can be concealed without being affected by the color tones of the lower adhesive layer 11 and the molding base material 21 when it is formed into a molded body. . In addition, it is preferable to use one having a glossy color tone so that good image clarity can be imparted. Further, metallic or pearly tone may be obtained by mixing fine metal powder, mica powder, glass powder and the like.

The transparent film 13 is made of an uncolored transparent paint composed of a synthetic resin and a solvent that dissolves them. As the synthetic resin of the transparent paint, it is preferable to use a synthetic resin having high transparency and gloss so that the colored coating film 12 as the lower layer can have a good glossy feeling when formed into a molded body. In addition, it is preferable to use a highly durable one so that the colored coating 12 can be effectively protected. Further, weather resistance may be imparted by mixing a weather resistance agent such as a hindered amine light stabilizer and a benzotriazole UV absorber.

Examples of the colored paint and the transparent paint used for the colored film 12 and the transparent film 13 include paints having a resin composition having a functional group such as a hydroxyl group, such as polyester, polyurethane and polyacrylic. In addition, you may mix | blend polyisocyanate etc. which have an isocyanate group which reacts with a hydroxyl group as a functional group as a hardening | curing agent. Further, in order to enhance the adhesiveness between the colored coating film 12 and the transparent film 13, it is preferable to use the same kind of synthetic resin for the colored coating material and the transparent coating material.
For the colored paint and the transparent paint of this embodiment, a one-pack type acrylic resin paint using a blocked isocyanate as a curing agent or a two-pack type acrylic resin paint using a polyisocyanate is selected and used as necessary. There is.

The transparent film 13 is the protective film 14
Spray coat, rotary spray coat,
It is formed by applying a transparent coating material by a method such as roll coating and drying. The colored coating film 12 is formed by applying a colored coating material to the back surface of the transparent film 13 by a method such as spray coating, rotary spray coating, or roll coating, and drying.

The transparent film 13 and the colored film 12 have a reaction rate between the resin in the paint and the curing agent of 0% or more and less than 80% in an uncured state (semi-curing state) according to JIS K at the time of molding of the molded body. The elongation at break specified by 6251 is 50 to
It is 250%. In addition, the adhesive layer 11 can be stretched corresponding to the transparent film 13 and the colored film 12 in the semi-curing state, so that the adhesive layer 11 can be stretched according to JIS K 62 at the time of molding the molded body.
The elongation at break defined by 51 is preferably 50 to 250%. When the elongation at break is less than 50%, the adhesive layer 11, the colored coating 12 and the transparent film 13 are broken during molding of the molded body, and it is not necessary to impart further elongation even if it is higher than 250%. The strength of the adhesive layer 11, the colored coating film 12, and the transparent film 13 is reduced. When the colored coating material and the transparent coating material are applied to the back surface of the protective film 14 and dried, the transparent film 13 and the colored coating film 12 are in a semi-curing state. In addition, in the cured state (curing state) in which the reaction rate of the resin in the paint and the curing agent is 80 to 100%, the elongation percentage at break of the transparent film 13 and the colored film 12 is preferably 10 to 100%.

The thickness of the adhesive layer 11 is 10 to 50 μm.
Is preferable, and it is more preferable that it is 15 to 40 μm. When the thickness of the adhesive layer 11 is less than 10 μm, its strength is lowered and defects such as cracks, breaks and scratches are likely to occur during molding of the molded body, and when the thickness is more than 50 μm, the adhesive layer 11 becomes hard. , Becomes difficult to stretch.

The thickness of the colored coating 12 is preferably 5 to 30 μm. When the thickness is less than 5 μm, the strength is lowered, and defects such as cracks, breaks, and scratches may occur when the colored coating 12 is extended. Thickness is 3
When the thickness is more than 0 μm, the colored coating 12 becomes hard and difficult to stretch.

The thickness of the transparent film 13 is preferably 5 to 50 μm, more preferably 15 to 40 μm. When the thickness of the transparent film 13 is less than 5 μm,
The sharpness of the molded product may be impaired, and the appearance of the molded product may deteriorate. Further, even if the thickness of the transparent film 13 is made thicker than 50 μm, the image clarity and the appearance are not further improved, and the manufacturing cost may be increased.

The protective film 14 is made of polyethylene,
It is made of a thermoplastic synthetic resin such as polyolefin such as polypropylene or polyester such as polyethylene terephthalate. As the thermoplastic synthetic resin forming the protective film 14, it is preferable to select a resin which is excellent in recyclability and in which gas is unlikely to flow out from the surface during heating or the like. Further, it is preferable to use, as the thermoplastic synthetic resin forming the protective film 14, a thermoplastic synthetic resin that does not completely adhere to the transparent film 13 and exhibits a predetermined adhesive force that is peelable. JIS
When the adhesion force of the protective film 14 to the transparent film 13 is expressed by the 180 ° direction peeling force specified by Z 0237,
The adhesive force is preferably 0.098 to 0.98 N / cm. If the adhesive force is less than 0.098 N / cm, the protective film 14 may be easily peeled off from the transparent film 13 and it may not be possible to protect it.
Further, when it is stronger than 0.98 N / cm, the transparent film 13 and the colored coating 12 are peeled off from the adhesive layer 11, or when the protective film 14 is peeled off after molding the molded body, the protective film 14 is hard to peel off from the surface of the molded body. There is a risk of becoming.

The thickness of the protective film 14 is 40 to 2000.
It is preferably μm. If the thickness is less than 40 μm, the rigidity tends to be low and defects such as cracks and fractures are likely to occur, and if the thickness is more than 2000 μm, it becomes hard and difficult to stretch, and it becomes difficult to mold the molded body into a predetermined shape. As shown in FIG. 2A, the protective film 1
No. 4 has a predetermined flexibility so that the decorative layer 22 can be evenly adhered to the upper surface of the molded base material 21 while maintaining good moldability during molding of the molded body. . When the flexibility of the protective film 14 is indicated by the elongation at break similarly to the above, the elongation at break is 50 to 250%.

When the elongation at break is less than 50%, the protective film 14 cannot be stretched in conformity with the surface shape of the molded body, and the molded base material 21 cannot be molded into a predetermined shape. In addition, the protective film 14 does not stretch and the decorative layer 22
Since only the ones tend to stretch in accordance with the shape of the molding substrate 21, wrinkles are formed on the colored coating 12 and the transparent film 13, and the decorative layer 22 is lifted or peeled off from the surface of the molding substrate 21. The problem of occurs. Also, 2
If it is higher than 50%, the decorative layer 22 cannot follow the elongation and is broken, or the rigidity is lowered, and the shape corresponding to the molded body cannot be maintained, so that the molded base material 21 is not formed.
Can not be molded accurately.

The sheet material 10 having the above structure is shown in FIG.
It is manufactured using a device as shown in (a) and (b). That is, as shown in FIG. 3A, the coating roller 31 that constitutes the coating apparatus for performing the roll coating method has a cylindrical shape and is rotatably supported in the direction of the arrow in the figure. On the side of the coating roller 31, a columnar measuring roller 32 is supported at a slight interval so as to be rotatable in the same direction as the coating roller 31. A spray nozzle 33 is installed below the coating roller 31. The coating material is sprayed from the spray nozzle 33 toward the peripheral surface of the coating roller 31, and the amount of the sprayed coating material is adjusted by the measuring roller 32 so that the coating material has a uniform thickness. A cylindrical delivery roller 34 is supported above the coating roller 31 so as to be rotatable in the opposite direction of the coating roller 31.

In the above coating apparatus, a protective film 14 which is previously formed into a sheet at another location is supplied from one side portion above the coating apparatus. The protective film 14 is moved downward by the delivery roller 34, and is pressed against the peripheral surface of the coating roller 31 in the middle thereof, so that the transparent coating is applied to the back surface thereof. After that, the transparent paint is dried by a heater (not shown) or the like to scatter the solvent in the paint, whereby the transparent film 13 is formed on the back surface of the protective film 14. Then, using the same coating device, a coloring paint is applied to the back surface of the transparent film 13 and dried to form a sheet 41a including the protective film 14, the transparent film 13 and the colored film 12.

At this time, the transparent paint and the colored paint are preferably dried at a drying temperature of 80 to 100 ° C. and a drying time of 30 to 60 minutes. Drying temperature is 80 ℃, Drying time is 3
If it is less than 0 minutes, the solvent in the paint may not be sufficiently scattered, and the appearance quality may be deteriorated. Also, the drying temperature is 100
If the temperature is higher than 0 ° C and the drying time is longer than 60 minutes, the crosslinking reaction of the ester-based, acrylic-based, and urethane-based resins in the coating material may proceed, and the coating material may be completely cured. Then, by drying at a drying temperature of 80 to 100 ° C. and a drying time of 30 to 60 minutes, the crosslinking reaction of the resin becomes 0 to 10 in the reaction rate.
It can be stopped at about%.

As shown in FIG. 3 (b), the cylindrical first supply drum 41 constituting the sticking device is rotatably supported on the most upstream side (left side in the figure) of the device, and The sheet 41a is held on the outer peripheral surface in a circularly wound state so that the colored coating film 12 is located on the outer peripheral side. A cylindrical second supply drum 42 is rotatably supported below the first supply drum 41, and a synthetic resin film forming the adhesive layer 11 is wound in an annular shape on the outer peripheral surface thereof. It is held in a state. The heater roller 43 and the driven roller 4 are provided on the downstream side (right side in the drawing) of the device with respect to the first supply drum 41 and the second supply drum 42.
4 are arranged vertically. A heater is installed inside the heater roller 43 (not shown).
Is to be heated.

First supply drum 41 and second supply drum 4
The sheet 41a and the synthetic resin film drawn out from the heater roller 43 and the driven roller 44 from 2 are heated and pressed against each other between the heater roller 43 and the driven roller 44. Then, the synthetic resin film is attached to the colored coating film 12 of the sheet 41a to manufacture the sheet material 10 including the adhesive layer 11. Further, the manufactured sheet material 10 is rotated by a pair of upper and lower pull-in rollers 45 and a take-up roller 46 arranged on the downstream side of the device with respect to the heater roller 43 and the driven roller 44.
It is collected in a state of being wound in an annular shape on the outer peripheral surface of the winding roller 46.

Next, a method of manufacturing the molded body will be described. The molded body obtained by using the above-mentioned sheet material 10 is an in-mold capable of integrating the decorative layer 22 on the surface of the molding base material 21 almost at the same time as molding the molding base material 21 into a predetermined shape. It is manufactured by the molding method. As shown in FIG. 4, a pair of molds 51a and 51b (fixed mold and movable mold) used in the in-mold molding method have a cavity 52 having the shape of a molded body formed therein when clamped. ing.

In order to mold a molded body by the in-mold molding method, first, the sheet material 10 is preliminarily shaped by a vacuum molding method so that the sheet material 10 has a shape similar to that of the molded body after molding. In this vacuum forming method, after heating and softening the sheet material 10, the sheet material 10 is placed on a vacuum forming die including only one of a female die and a male die to form a gap between the sheet material 10 and the die. Is evacuated and the sheet material 10 is brought into close contact with the surface of the mold to be molded into a predetermined shape. Then, in the sheet material 10 at the time of preliminary shaping, the colored film 12 and the transparent film 13
Is a reaction rate of 30-
It is promoted up to about 60%.

The heating during the preliminary shaping is performed at a temperature of 100 to 160.
It is preferable to carry out the treatment at a temperature of 11 to 50 seconds for 10 to 50 seconds.
It is more preferable to carry out at 0 to 150 ° C. for 10 to 30 seconds. When the temperature is 100 ° C. and the time is less than 10 seconds, the protective film 14 does not soften sufficiently and does not extend, and thus it may not be possible to preform the desired shape. Further, when the temperature is higher than 160 ° C. and the time is longer than 50 seconds, the colored coating 12 and the transparent coating 13 are completely hardened, do not have sufficient elongation, and may be broken into preliminary shaping or the like. There is.

After preforming by the vacuum forming method, the sheet material 10 is cooled and taken out from the mold with its shape fixed. Thereafter, the sheet material 10 is heated and dried to accelerate the crosslinking reaction of the resin in the coating material until the reaction rate reaches 80 to 100%, and the colored film 12 and the transparent film 13 are brought into a curing state.

The heating and drying until the curing state is preferably carried out at a drying temperature of 100 to 160 ° C. and a drying time of 1 to 5 minutes, and a temperature of 110 to 150 ° C. and a time of 1 to 3 minutes.
More preferably, it is performed in minutes. When the drying temperature is 100 ° C. and the drying time is less than 1 minute, the cross-linking reaction of the resin in the paint may not be completed completely and the colored coating 12 and the transparent coating 13 may remain in the semi-curing state. If the injection molding method is performed in the semi-curing state, the transparent film 13 is damaged, the pressure when the resin material is injected in the vicinity of the gate in the mold, or the melting due to the heat from the melted resin material As a result, the transparent film 13 and the colored film 12 may flow together with the resin material. Drying temperature is 160
If the temperature is higher than 0 ° C and the drying time is longer than 5 minutes, the preformed sheet material 10 may be thermally deformed.

Next, as shown in FIG. 4, the sheet material 10 preformed as described above has a pair of molds 51.
After being housed in the cavity 52 of a and 51b while being positioned and fixed, the pair of molds 51a and 51b are clamped. Then, the synthetic resin material that is heated and melted to form the molding substrate 21 in the cavity 52 is injected at a predetermined pressure from a gate (not shown) on the adhesive layer 11 side of the sheet material 10. Then, the sheet material 10 is deformed according to the shape of the cavity 52 by the pressure and the temperature when the synthetic resin material is injected.

At this time, the transparent film 13 is the protective film 14
This prevents direct contact with the inner surface of the mold 51a, and prevents problems such as sticking of the decorative layer 22 to the inner surface of the mold 51a, scratching of the transparent film 13, peeling, and sore caused by melting. . Further, since the protective film 14 is made of a material from which gas is difficult to flow out during heating,
It is possible to prevent gas from being generated from the protective film 14 that is in contact with the inner surface of the mold 51a to form bubbles on the surface of the transparent film 13, so that good appearance quality is maintained.
In addition, the adhesive layer 11, the molding substrate 21 and the colored coating 12
At the boundary portion between and, the colored films 12 are fused to the surface of the molding substrate 21 via the adhesive layer 11 by thermal fusion of the synthetic resins forming each other.

After the molds 51a and 51b are sufficiently cooled from the outside, the pair of molds 51a and 51b are opened, and as shown in FIG.
As shown in (a), the molded body with the protective film 14 attached is taken out. Then, the protective film 14 is removed as shown by the two-dot chain line in FIG.
A molded body is manufactured. In addition, the removed protective film 14 is recycled to produce another sheet material 10
Can be used as a material for manufacturing.

The effects exerted by the above embodiment will be described below. -According to the embodiment, by providing the colored coating film 12 made of a colored paint and the transparent film 13 made of a transparent paint laminated on the surface of the molding substrate 21, a good cleanness can be obtained on the surface of the molded body. It is possible to add image clarity and a glossy feeling, and its texture is enhanced.
In the sheet material 10 for obtaining such a molded body,
Protective film 14 for protecting the surface of the transparent film 13
Has a breaking elongation of 50 to 250% and has flexibility. Therefore, the colored film 12 and the transparent film 13 have the same flexibility as that of the protective film 14, and when a molded product is obtained by the in-mold molding method, the sheet material corresponding to the surface shape of the molding base material 21 is obtained. It is possible to extend 10 sufficiently. Then, it is possible to prevent deterioration of the texture such as the transparent film 13 and the colored film 12 breaking or wrinkling.

In addition, the molding material 2 is made of the sheet material 10.
By providing the colored coating film 12 on the surface of No. 1, it is possible to suppress the scattering of the volatile solvent into the air and maintain the environment in good condition, as compared with the conventional coating of the paint on the surface of the molding substrate 21. it can. In addition, by using the molding base material 21, the adhesive layer 11, the colored coating film 12, and the transparent film 13 of the same type of material, the used molding product can be recycled.

By providing the adhesive layer 11 on the back surface of the colored coating 12, the colored coating 12 on the surface of the molding substrate 21
Can be reliably attached. According to the manufacturing method of the sheet material 10 of the embodiment, the colored coating film 12 and the transparent film 13 can be easily formed. Furthermore, when performing pre-shaping before molding the molded body, since the colored film 12 and the transparent film 13 in the semi-curing state have elongation, it is possible to prevent problems such as breakage or damage during molding. You can

According to the method for manufacturing a molded body of the embodiment, the molding substrate 21 can be molded in one step, and the colored film 12 and the transparent film 13 can be simultaneously formed on the surface of the molded substrate 21, and thus the coating can be performed. It can be easily manufactured while maintaining its appearance quality.

[0047]

EXAMPLES Hereinafter, examples in which the above embodiment is further embodied will be described. (Example 1) A transparent coating material and a colored coating material were sequentially applied by a spray coating method on a protective film 14 made of unstretched polypropylene (PP) and having a thickness of 100 µm and a breaking elongation of 50 to 250%. As this coating material, a one-pack type modified acrylic resin coating material (manufactured by Fujikura Kasei Co., Ltd., trade name EXP-4785) using blocked isocyanate as a curing agent was used. After this, at 80 to 100 ° C. for 30 to 60 minutes,
The paint was dried to form a transparent film 13 and a colored film 12. At this time, the transparent film 13 and the colored film 12 formed an uncured coating film. Then, the adhesive layer 11 was formed on the colored coating film 12. The transparent film 13, the colored film 12, and the adhesive layer 11 were formed so that the total thickness of them was 60 μm. In this way, the sheet material 1 of Example 1
I got 0. (Example 2) Made of unstretched PP and having a thickness of 200 μm,
As in Example 1, the transparent film 13, the colored film 12, and the adhesive layer 11 were formed on the protective film 14 having a breaking elongation of 50 to 250% so as to have a total thickness of 60 μm. As the paint, a one-pack type modified acrylic resin paint (trade name EXP-4785 manufactured by Fujikura Kasei Co., Ltd.) using block cyanate as a curing agent was used. The formed transparent film 13 and the colored film 12 formed an uncured coating film. Thus, the sheet material 10 of Example 2 was obtained. (Example 3) Made of unstretched PP and having a thickness of 100 μm,
As in Example 1, the transparent film 13, the colored film 12, and the adhesive layer 11 were formed on the protective film 14 having a breaking elongation of 50 to 250% so as to have a total thickness of 60 μm. As the coating material, a two-pack type modified acrylic resin coating material (trade name: Lecrack 440 manufactured by Fujikura Kasei Co., Ltd.) using polyisocyanate as a curing agent was used. The formed transparent film 13 and the colored film 12 formed an uncured coating film. In this way, the sheet material 10 of Example 3 was obtained. (Comparative Example 1) Made of unstretched PP and having a thickness of 100 μm,
A transparent coating material and a colored coating material were applied in order on the protective film 14 having a breaking elongation of 50 to 250% by a spray coating method. For this paint, a two-pack type modified acrylic resin paint using Polyisocyanate as a curing agent (trade name: Lecrack 440 manufactured by Fujikura Kasei Co., Ltd.) was used. Then, the coating material was dried until the transparent film 13 and the colored coating film 12 were completely cured. Then, the adhesive layer 11 was formed on the colored coating film 12. The transparent film 13, the colored film 12, and the adhesive layer 11 were formed so that the total thickness of them was 60 μm. In this way, the sheet material 10 of Comparative Example 1 was obtained. (Comparative Example 2) Made of unstretched PP and having a thickness of 100 μm,
A transparent coating material and a colored coating material were applied in order on the protective film 14 having a breaking elongation of 50 to 250% by a spray coating method. For this coating, a two-pack type modified polyester resin coating containing a polyisocyanate crosslinking agent (trade name: Softcoat 2071 manufactured by Fujikura Kasei Co., Ltd.) was used. After this,
The coating material was dried until the transparent film 13 and the colored film 12 were completely cured. Then, the adhesive layer 11 was formed on the colored coating film 12. The transparent film 13, the colored film 12, and the adhesive layer 11 were formed so that the total thickness of them was 60 μm. In this way, the sheet material 10 of Comparative Example 2 was obtained. (Measurement of Change in Appearance by Vacuum Forming Method) Sheet materials 10 of Examples 1 to 3 and Comparative Examples 1 and 2 are formed into a rectangular box shape by a vacuum forming method, and changes in appearance of each sheet material 10 are measured. did. For vacuum forming, the upper surface of each sheet material 10 is heated at 130 ° C. for 25 seconds using an infrared heater, and then the temperature is set to 25 ° C.
Molding was performed for 60 seconds (including a cooling time of 30 seconds) using the vacuum molding die of. Then, each sheet material 10 was stretched at each elongation of 50, 150, and 250% and vacuum-formed, and then appearance changes such as cracks and breaks of the colored coating 12 and the transparent coating 13 were measured. The results are shown in Table 1. The measurement was performed by a measurer visually observing the transparent film 13 and the colored film 12 through the protective film 14.
Further, in Table 1, ◯ indicates no change in appearance, Δ indicates cracks or breaks in a part of the transparent film 13 and the colored coating 12, and changes in appearance. × indicates transparent film 13 and colored coating 1.
It shows that cracks and fractures occurred in almost all of No. 2, and there was a significant change in appearance.

[0048]

[Table 1] From the results of Table 1, Examples 1 to 3 have elongation rates of 50 and 150.
And transparent film 13 at all elongations of 250%
Also, there was no change in the appearance of the colored coating film 12, and good results were obtained. On the other hand, in Comparative Example 1, when the elongation rate is 50%, cracks and fractures occur in a part of the transparent film 13 and the colored coating film 12, and when the elongation rates are 150 and 250%, the transparent film 13 and the colored coating film 12 are almost the same. Since the entire surface was cracked or fractured, its appearance changed significantly. Comparative example 2 has elongation rates of 50 and 1
At all of the elongation rates of 50 and 250%, cracks, fractures, etc. occurred in a part of the transparent film 13 and the colored film 12, so that the appearance thereof changed.

From the above results, Comparative Examples 1 and 2 are transparent film 1
3 and the colored coating film 12 become a coating film in a completely cured state, so that it is difficult to maintain flexibility and the protective film 14
It was shown that it was not possible to cope with the elongation of the steel, and cracks and fractures occurred. On the other hand, the transparent film 13 and the colored coating film 12 of Examples 1 to 3 have a large elongation as compared with Comparative Examples 1 and 2 because the transparent film 13 and the colored coating film 12 are in an uncured state and thus retain flexibility. is doing. Therefore, the transparent film 13 and the colored film 12 of Examples 1 to 3 can cope with the elongation of the protective film 14 and can reliably prevent changes in appearance such as cracks and breaks during vacuum forming. It has been shown.

Further, with respect to Example 1, the glossiness and the sharpness after the molding by the vacuum molding method were evaluated. After applying the alkyd melamine-based paint to an electrodeposited plate with a thickness of 0.8 mm, apply acrylic clear paint on the surface,
It was compared with the glossiness and sharpness of the conventional outer panel coated product whose color tone was silver metallic. The results are shown in Table 2.
The glossiness was measured according to the method specified in JIS Z 8741 by setting the angle between the light projecting portion and the light receiving portion to 60 ° and measuring the 60 ° specular glossiness. Also, the clarity is PG
The measurement was performed using a T5 type image clarity gloss meter (manufactured by Japan Color Research Institute).

[0051]

[Table 2] From the results in Table 2, the unstretched and stretched transparent film 13 having a elongation of 50%
The colored coating 12 and the colored coating 12 have a gloss of 92 and a freshness of 1.2 and 1.0, respectively, and the conventional outer coating product has a gloss of 93 and a freshness of 1.2. , There was almost no difference. Also, at elongations of 150 and 250%, the glossiness is 90 and 89, respectively, and the sharpness is 0.8, respectively, showing a slight decrease as compared with the conventional outer panel coated product, but it is almost comparable. It became nothing. From the above results, it is shown that when the sheet material 10 is used, there is no significant difference in glossiness and sharpness as compared with the conventional product, and it can be sufficiently used as an alternative means of coating. . (Measurement of Appearance by Injection Molding Method) The preformed sheet materials 10 of Examples 1 and 2 are heated and dried at a drying temperature of 100 to 160 ° C. for a drying time of 1 to 5 minutes to form a completely cured coating film. After that, each was placed in a mold and a molded body was obtained by an injection molding method. The injection molding method uses 195 heat-melted PP (trade name Novatec manufactured by Japan Polychem) in the mold.
It was carried out by injecting at a temperature of 9.8 MPa and a pressure of 9.8 MPa. Then, with respect to each of the obtained molded products, a change of the appearance of the transparent film 13 and the colored film 12 was visually observed by a measurer to measure. As a result, in Examples 1 and 2, there was no change in appearance and good molded products were obtained. From the above results, the transparent film 13 and the colored film 12 of Examples 1 and 2 have sufficient durability against high temperature and high pressure in the injection molding method, and can maintain a good texture of the molded product. It was shown that it was possible.

Next, using Examples 1 and 2, the molded articles obtained were evaluated for solvent resistance, scratch resistance, weather resistance and appearance of the surface. The results are shown in Table 3. The solvent resistance was evaluated by immersing the molded body in gasoline for 30 minutes and then visually observing the surface of the molded body. The scratch resistance was evaluated by sliding a nylon pile brush on the surface of the molded body 50 times and then visually observing the surface. The weather resistance was evaluated by irradiating the surface of the molded article with WOM (BP 63 ° C.) for 1000 hours,
The surface was visually observed by a measurer. The appearance was evaluated by a measurer visually observing the surface of the molded body. Further, in Table 3, the evaluation results are shown in three grades of good, good, good, and bad in order.

[0053]

[Table 3] From the results of Table 3, in Examples 1 and 2, good results were obtained in evaluation of solvent resistance and weather resistance, and scratch resistance was low,
The result was excellent in gloss and image clarity. From the above results, the transparent film 13 and the colored film 1 of Examples 1 and 2
No. 2 was found to have good appearance and high solvent resistance, scratch resistance and weather resistance.

The embodiment can be modified and embodied as follows. The color tone of the transparent film 13 is not limited to non-colored transparent, and may be colored transparent such as red, blue, yellow and brown. Further, a matting agent may be added to the composition to make it semi-matt or matt. In addition, mica powder, pearl powder, metal powder or the like may be blended to obtain a color tone such as pearl tone, mica tone or metallic tone.

The coloring film 12 may have a color tone of, for example, red, blue, yellow, brown or the like depending on the pigment, or may have a white color which is the original color tone of the resin without mixing the pigment. Further, it may be colored and transparent.

In the embodiment, the molding of the molded body by the in-mold molding method is embodied by the injection molding method, but the present invention is not limited to this, and may be embodied by a vacuum molding method, a blow molding method, an extrusion molding method, or the like.

In the embodiment, the colored coating film 12 is formed by the roll coating method, but it may be formed by the spray coating method or the screen printing method. The sheet material 10 and the molded body may be formed by omitting the adhesive layer 11. When the adhesive layer 11 is omitted, the colored coating 12 also functions as an adhesive layer, so that the synthetic resins forming each other at the boundary between the molding substrate 21 and the colored coating 12 are heat-sealed. . Therefore, when the adhesive layer 11 is omitted, the colored coating film 1
The synthetic resin forming 2 and the synthetic resin forming the molding substrate 21 are preferably selected so that they can be heat-sealed to each other.

The drying for bringing into a curing state may be omitted, and the colored film 12 and the transparent film 13 may be held in a semi-curing state. -The adhesive layer 1
1 may be formed by applying a polyurethane adhesive, a polyacrylic adhesive, an epoxy resin adhesive, or the like on the back surface of the colored coating film 12.

When the molded body is molded by the in-mold molding method, the sheet material 10 may be pre-shaped by the blow molding method. Alternatively, the sheet material 10 may be directly placed in the cavity 52 of the pair of molds 51a and 51b without performing the preliminary shaping.

Further, the technical idea which can be understood from the above embodiment will be described below. The colored coating material and the transparent coating material that form the colored coating film and the transparent coating material, respectively, are ester-based having a functional group that reacts with an isocyanate group,
A sheet material for coating substitution according to claim 1 or 2, which is a one-pack type or two-pack type coating material obtained by blending urethane or acrylic resin with polyisocyanate as a cross-linking agent. . With this configuration, the curing time and the degree of curing of the colored coating can be easily adjusted.

The coating substitute sheet material according to claim 1 or 2, wherein the colored coating film has a thickness of 5 to 30 µm. With such a configuration, it is possible to obtain a product having excellent moldability while maintaining the strength of the colored film.

The coating substitute sheet material according to claim 1 or 2, wherein the transparent film has a thickness of 5 to 50 μm. With such a configuration, it is possible to obtain a product having excellent moldability while maintaining the strength of the colored film.

The protective film has a thickness of 40 to 2
It is 000 micrometers, The sheet material for coating substitution of Claim 1 or Claim 2 characterized by the above-mentioned. With such a configuration, it is possible to maintain a predetermined rigidity while imparting appropriate flexibility to the protective film.

The sheet material for coating substitution according to claim 1 or 2 is preshaped by a vacuum molding method or a blow molding method so as to have a shape similar to that of a molded body after molding, and then a pair is formed. It arrange | positions in the cavity of the metal mold | die of this, The manufacturing method of the molded object of Claim 5 characterized by the above-mentioned. When configured in this manner, when the molded body is molded, even if the surface has a complicated shape such as a large number of irregularities and the curvature greatly changes on a continuous surface, the texture obtained by the in-mold molding method Can be sufficiently dealt with while suppressing the decrease of

[0065]

As described in detail above, the present invention has the following effects. According to the invention described in claim 1 or 5, it is possible to suppress the deterioration of the texture due to the in-mold molding method.

According to the invention described in claim 2, claim 1
In addition to the effects of the invention described in 1, deep in the color tone of the colored film,
It is possible to impart sharpness and glossiness and improve the texture of the molded product.

According to the invention of claim 3, claim 1
Alternatively, in addition to the effect of the invention described in claim 2, it is possible to ensure the adhesion of the colored film to the surface of the molding substrate. According to the invention described in claim 4 or 6, it is possible to easily manufacture a coating substitute sheet material or a molded body that can suppress deterioration of texture due to the in-mold molding method.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a coating substitute sheet material according to an embodiment.

FIG. 2A is a sectional view showing a molded body before peeling off a protective film, and FIG. 2B is a sectional view showing the molded body.

3A is a conceptual diagram showing a coating device, and FIG. 3B is a conceptual diagram showing a device for laminating an adhesive layer on a colored film.

FIG. 4 is a cross-sectional view showing a state in which a molded body is molded by an in-mold molding method.

[Explanation of symbols]

10 ... Sheet material as alternative sheet material for coating, 12 ... Colored film, 13 ... Transparent film, 14 ... Protective film, 21 ... Molding base material, 51a, 51b ... Mold, 52 ... Cavity.

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Ryuichi Yamada             2-9-29, Kamemazu, Naka-ku, Nagoya-shi, Aichi               Mallet indoor (72) Inventor Genji Ohama             2-9-29, Kamemazu, Naka-ku, Nagoya-shi, Aichi               Mallet indoor (72) Inventor Yuya Dejima             Saitama Prefecture Kitakatsushika-gun Washimiya-cho 5-13-1, Sakurada Fuji             Kurashisei Co., Ltd. F term (reference) 4F100 AK01A AK01B AK01C AK01D                       AK07 AK25 AR00D BA02                       BA03 BA04 BA07 BA10A                       BA10B BA10D BA15 CA02                       CC00 EH112 EH362 EH46                       EH462 GB32 GB33 GB36                       HB00A JB16B JK08 JL02                       JL10A JL11D JM02C JN01C                       JN21 YY00                 4F206 AD09 AD20 AG03 AH26 JA07                       JB13 JB19 JF05 JW21

Claims (6)

[Claims] 1. When molding a synthetic resin molding substrate into a predetermined shape, it is used in an in-mold molding method in which a colored film is formed on the surface of the molding substrate to obtain a molded body, and as an alternative means of coating. A sheet material for coating substitution used, comprising a colored film formed of a synthetic resin and a protective film formed of a thermoplastic resin laminated on the surface of the colored film, The film is a sheet material for coating substitution, which has a breaking elongation defined by JIS K 6251 of 50 to 250% at the time of molding of a molded body. 2. A transparent film formed of a transparent synthetic resin is laminated on the surface of the colored film, the transparent film is disposed between the colored film and the protective film, and the transparent film is formed of a molded product. The sheet material for coating substitution according to claim 1, wherein the elongation at break defined by JIS K 6251 at the time of molding is 50 to 250%. 3. The coating substitute sheet material according to claim 1, wherein an adhesive layer is provided on the back surface of the colored coating film. 4. A protective film made of a thermoplastic resin is formed, a transparent film made of synthetic resin is formed on the back surface of the protective film, and then a colored coating film made of synthetic resin is laminated on the back surface of the transparent film. A method for producing the coating substitute sheet material according to claim 2 or 3. 5. A molding base material made of a synthetic resin and having a predetermined shape, which is obtained by an in-mold molding method using the coating substitute sheet material according to claim 2 or 3, and the surface of the molding base material. A molded product, comprising: a colored film adhered to the substrate; and a transparent film formed on the surface of the colored film. 6. The coating substitute sheet material according to claim 2 or 3 is arranged in a cavity of a pair of molds, and is provided on the colored coating side of the coating substitute sheet material in both molds. After injecting the heated and melted synthetic resin material that forms the molding base material from the gate that was cooled, by cooling both molds,
Almost at the same time as the molding of the molding base material, the colored coating film is heat-fused on the surface of the molding base material to integrate the molding base material, the colored coating film and the transparent film. A method for producing a molded article, which comprises removing the protective film from the surface.