JP2003200502A - Decorative member manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative member manufacturing method capable of easily obtaining a decorative member having an arbitrary fine uneven shape. <P>SOLUTION: A substrate sheet 3 comprises at least a single-layer film comprising a resin selected from a polycarbonate resin, a polycarbonate/ polyethyleneterephthalate alloy resin and a polycarbonate/ polybutyleneterephthalate alloy resin or a composite-layer film having the single- layer film laminated on the outermost surface thereof. A decorative sheet 2 comprising at least the sheet 3 and a decorative layer 4 is softened under heating and arranged so that the substrate sheet 3 thereof is opposed to a performing mold 6 having a fine uneven shape 7 formed thereon, and subsequently preformed along the surface of the performing mold 6. Next, the decorative sheet 2 is arranged in a mold 8, and a molten resin is injected in the mold 8 to be integrated with the decorative sheet 2. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a decorative member that can be used for a mobile phone, a home electric appliance, an automobile part, a push button switch of a communication device and the like.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a decorative member having a fine unevenness on the surface, a base sheet having a fine unevenness on the entire surface is preformed so as to match the three-dimensional shape of a molding die. Next, there is a method of setting in a molding die and injecting a molten resin into the molding die to integrate the decorating sheet and the molten resin to obtain a decorating member having fine irregularities on the surface.

In this method, as the base sheet,
Considering the surface protection function and transportability to the molding process, heat resistance,
It is usual to use a resin made of a polycarbonate-based resin or a polycarbonate alloy-based resin having excellent impact resistance and chemical resistance. Further, the fine concavo-convex shape on the surface of the base sheet is formed by transferring the fine concavo-convex shape on the surface of the embossing roll using an embossing roll in the manufacturing process of the base sheet.

In such a base sheet, the surface of the base sheet is not softened even when the molten resin is injected into the molding die to integrate the decoration sheet and the molten resin, so that the cavity surface of the molding die is not softened. The fine concavo-convex shape can be maintained regardless of the surface shape. Therefore, it is possible to obtain a decorating member having on its surface a fine concavo-convex shape imparted at the time of manufacturing the base sheet.

[0005]

However, in the above-described method for producing a decorative member, since the embossing roll used for producing the base sheet is very expensive, the fine uneven shape is a film for producing the base sheet. In reality, it is inevitable to select from the embossing rolls owned by the manufacturer, and there is a problem that it is difficult to give an arbitrary fine uneven shape to the surface of the decorative member.

Therefore, an object of the present invention is to provide a method for manufacturing a decorative member which solves the above problems and can easily obtain a decorative member having an arbitrary fine uneven shape. .

[0007]

The method for manufacturing a decorative member of the present invention is configured as follows in order to achieve the above object.

That is, the method for producing a decorative member of the present invention is a single layer film selected from a polycarbonate resin, a polycarbonate-polyethylene terephthalate alloy resin or a polycarbonate-polybutylene terephthalate alloy resin, or the above single layer. The base sheet side of the heat-softened decorative sheet comprising at least a base sheet made of a multilayer film in which the film is laminated on the outermost surface side and a decorative layer is faced to a preforming mold in which fine irregularities are formed. Installed, then preform the decorative sheet along the surface of the preforming mold, then install the decorative sheet in the molding die and inject the molten resin so that the decorative sheet and the molten resin are integrated. Configured.

Further, in the above invention, the pre-molding die may be configured such that the fine concavo-convex shape is partially formed.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view showing an embodiment of a decorative member obtained by the method for manufacturing a decorative member of the present invention. 2-7 is sectional drawing which shows 1 process of the manufacturing method of the decoration member of this invention. In the figure, 1 is a decorative member, 2 is a decorative sheet, 3 is a base sheet, 4 is a decorative layer, 5 is an adhesive layer, 6 is a preforming die, 7 is a fine concavo-convex shape, 8 is a molding die, 9 Is a gate, and 10 is a molding resin.

The method for manufacturing the decorative member 1 of the present invention is a polycarbonate resin, a polycarbonate-polyethylene terephthalate alloy resin or a polycarbonate resin.
Base sheet 3 comprising a monolayer film selected from any of polybutylene terephthalate alloy resins or a multilayer film in which the monolayer film is laminated on the outermost surface side
The base sheet 3 side of the heat-softened decorative sheet 2 including at least the decorative sheet 4 and the decorative layer 4 is installed so as to face the preforming mold 6 having the fine irregularities 7 formed thereon, and then the decorative sheet 2 is preformed. This is a method of pre-molding along the surface of the mold 6, then placing the decorative sheet 2 in the molding die 8 and injecting the molten resin to integrate the decorative sheet 2 and the molten resin (FIGS. 1 to 7). reference).

First, the heat-softened decorative sheet 2 is placed so that the base sheet 3 side faces the preforming die 6 (see FIG. 2).

The decorative sheet 2 includes a base sheet 3 and a decorative layer 4.
And at least consist of.

As the base sheet 3, a single layer film selected from a polycarbonate resin, a polycarbonate-polyethylene terephthalate alloy resin or a polycarbonate-polybutylene terephthalate alloy resin, or the single layer film is laminated on the outermost surface side. The multilayer film thus prepared is used.

The base sheet 3 has a softening temperature of 80 to 30 in particular.
It is preferable to use one having a high temperature of 0 ° C. If the softening temperature is less than 80 ° C., the heat-resistance (80 to 100 ° C., 12 to 24 hours) required for the decorative member 1 may soften the fine uneven shapes 7 and change the appearance. Further, it may not be able to endure the drying heat when the decorative layer 4 is formed by various printing methods, and dimensional shrinkage may occur, which may make accurate registration of the decorative layers 4 difficult. If the softening temperature exceeds 300 ° C., the heating temperature in the preforming step must be increased and the heating time must be lengthened, which may make it difficult to preform the decorative layer 4 in a desired position. There is.

The thickness of the base sheet 3 is 50 to 250 μm.
It is good to use the thing of the range of. If the thickness is less than 50 μm, the film forming process is difficult and the handling in each process tends to be poor. Further, the elongation at the time of preforming cannot be followed, and the risk of breakage at a thin portion increases.

The decorative layer 4 is formed on the base sheet 3. The decorative layer 4 is a layer for expressing a pattern or the like.
The decorative layer 4 is usually formed as a printed layer. As the material of the printed layer, polyvinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, resin such as alkyd resin is used as a binder. It is preferable to use a colored ink containing a pigment or dye of an appropriate color as a colorant. In addition, a metallic luster color can be expressed by using an ink in which metal powder such as aluminum is used as a pigment. As a method of forming the printing layer, an offset printing method,
A normal printing method such as a gravure printing method or a screen printing method may be used. The print layer may be formed wholly or partially according to the desired design.

The printed layer is preferably formed with a thickness of 1 to 30 μm. If the film thickness is less than 1 μm, sufficient coloring cannot be expressed, and the thickness at the extended portion may be too thin during preforming, and cracks or light leakage may occur. Also,
If the film thickness exceeds 30 μm, it may be impossible to sufficiently reproduce the shape at the corners or the like during preforming. Further, since the residual solvent in the printed layer is less likely to volatilize, the mold release property is deteriorated during preforming, and the ink flow easily occurs when the molten resin comes into contact with the resin.

The decorative layer 4 may be a metal thin film layer or a combination of a printing layer and a metal thin film layer. The metal thin film layer is for expressing a metallic luster color as the decorative layer 4, and is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method or the like. Depending on the desired metallic luster color, metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, alloys or compounds thereof are used. The metal thin film layer has a film thickness of 1
The thickness is preferably 0 to 40 nm. Film thickness 10 nm
If the thickness is less than 4, it is difficult to control the film thickness in the vapor deposition process.
If it exceeds 0 nm, there is concern about corrosion. Further, the metal thin film layer can be formed entirely or partially. As a method for partially forming the metal thin film layer, a masking layer is partially formed on the metal thin film layer formed on the entire surface of the base sheet 3 by a screen printing method or the like, and then the metal thin film layer is immersed in an acid or alkali aqueous solution to perform masking. There is an etching method for removing the metal thin film layer other than the portion where the layers are laminated. Further, there is a laser marking method in which a light shielding layer is entirely formed on a metal thin film layer formed on the entire surface of the base sheet 3, and then the metal thin film layer and the light shielding layer are removed into a desired pattern shape by a laser beam.

Particularly, in the present invention, the base sheet 3
Since the fine concavo-convex shape 7 formed on the surface can be sharp and highly transparent, by forming a layer expressing metallic luster with a metallic pigment or a metallic thin film, excellent matte and metallic luster can be obtained. It is possible to express a metallic luster pattern that has both.

Further, in the present invention, the base sheet 3
Since the fine unevenness 7 formed on the surface can be made into a hairline shape that is excellent in transparency and has a higher degree of fineness than the cutting hairline, a fine hairline-like metallic luster pattern like a stainless steel plate subjected to hairline processing It becomes possible to express.

The decorative member 1 is formed by partially forming the decorative layer 4 as a layer having a light shielding property.
The light source may be arranged on the back side of the so as to express patterns such as characters and symbols. Further, by forming the translucent decorative layer 4 in a portion where the decorative layer 4 as described above is not formed, colored letters and the like when the light source is arranged on the back surface side of the decorative member 1 and It can also be configured to represent patterns such as symbols.

If desired, the adhesive layer 5 may be formed. The adhesive layer 5 is a layer for adhering the above layers onto the molding resin 10. As the adhesive layer 5, a heat-sensitive or pressure-sensitive resin suitable for the material of the molding resin 10 is appropriately used.
For example, when the molding resin 10 is made of acrylic resin, acrylic resin may be used. Also, the molding resin 10
When the material is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, or a styrene copolymer resin, an acrylic resin, a polystyrene resin, a polyamide resin, or the like having an affinity for these resins may be used. Further, when the material of the molding resin 10 is polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber and coumarone indene resin can be used. As a method of forming the adhesive layer 5, there are a coating method such as a gravure coating method, a roll coating method and a comma coating method, and a printing method such as a gravure printing method and a screen printing method. The adhesive layer 5 has a film thickness of 1 to 30 μm.
It is preferably formed by m. If the film thickness is less than 1 μm, sufficient adhesion with the molding resin 10 may not be obtained. When the film thickness exceeds 30 μm, it becomes difficult to form it by various coating methods or printing methods. It is also possible to bond the sheets made of the above-mentioned materials and having an adhesive property by a laminating method or the like to form the adhesive layer 5. Further, the adhesive layer 5 may be transparent or translucent. Further, it may be colored so that it can also be used as the light-shielding colored layer or the light-transmitting colored layer.

An anchor layer may be provided between these layers (not shown). The anchor layer is a layer for enhancing the adhesion between the layers and protecting the molding resin 10, the decorative layer 4 and the like from chemicals. For example, a two-component curable urethane resin, a melamine resin or an epoxy resin is used. A thermosetting resin such as a system resin and a thermoplastic resin such as a vinyl chloride copolymer resin can be used. In particular, it is preferable to use an acrylic polyol resin having excellent transparency, heat resistance, and flexibility between the base sheet 3 and the metal thin film layer. As a method for forming the anchor layer, a coating method such as a gravure coating method, a roll coating method or a comma coating method, a gravure printing method,
There is a printing method such as a screen printing method.

As the preforming mold 6, a mold having fine irregularities 7 formed on its surface is used. The fine uneven shape 7 represents a matte pattern, a hairline pattern, a spin pattern, and the like. The fine concavo-convex shape 7 may be formed by a sandblasting method, an electrode electric discharge machining method, an NC machining method, or the like. The uneven depth can be appropriately selected according to the desired fine uneven shape 7. The fine concavo-convex shape 7 of the preforming die 6 may be partially formed. In order to partially form the fine concavo-convex shape 7, in addition to the above processing methods, a mold member having a polished surface may be inserted with a part of the molding die 8 being nested. As described above, since the fine concavo-convex shape 7 expresses an arbitrary pattern, it can be formed with an arbitrary concavo-convex depth and an arbitrary pattern.

Next, using the decorative sheet 2 and the preforming die 6 having such a configuration, preforming is performed so that the decorative sheet 2 is along the surface of the preforming die 6 (see FIG. 3).

In the preforming step, the fine concavo-convex shape 7 on the surface of the preforming die 6 is transferred to the surface of the base sheet 3 of the decorative sheet 2, and the entire decorative sheet 2 is deformed into a desired three-dimensional shape if necessary. It is a process. When the shape of the portion of the decorating member 1 where the decorating sheet 2 is integrated is flat, it is not necessary to deform the decorating sheet 2 into a three-dimensional shape.

For preforming, it is preferable to use a high pressure forming method, a hydraulic forming method, a pressure forming method, a vacuum forming method, a pressure air vacuum forming method, or the like. The conditions for preforming include the decorative sheet 2
It is preferable to heat and soften so as to have a surface temperature of 100 to 180 ° C., and then apply a load of about 8.0 to 20.0 MPa to deform it along the surface of the preforming die 6.
When the surface temperature of the decorative sheet 2 is less than 100 ° C., the heating and softening is insufficient, and thus the fine irregularities 7 on the surface of the preforming die 6 may not be transferred to the surface of the base sheet 3. If the heating temperature exceeds 180 ° C., the decorative sheet 2 is excessively softened by heating and the expansion and contraction of the decorative sheet 2 is increased, and thus it may not be possible to perform preforming while maintaining desired positional accuracy.

The decorative sheet 2 is preformed as described above (see FIG. 4).

Next, the decorative sheet 2 is placed in the molding die 8 and the molten resin is injected to integrate the decorative sheet 2 and the molten resin.

First, the decorative sheet 2 is fed into the molding die 8 (see FIG. 5).

The molding die 8 is a die which can obtain the decorative member 1 by sandwiching the decorative sheet 2 in the molding die 8 and injecting the molten resin. For example, the decorative member It is possible to use a mold capable of forming a cavity from one mold having a concave part forming the front side of 1 and the other mold having a convex part forming the back side of the decorative member 1. Further, the cavity surface may be smooth. Because the polycarbonate-based resin, the polycarbonate-polyethylene terephthalate alloy-based resin, and the polycarbonate-polybutylene terephthalate alloy-based resin used in the base sheet 3 in the present invention have high heat resistance, the molten resin flows into the cavity, This is because even if the decorative sheet 2 is contacted and the cavity is filled, the surface of the base sheet 3 is not softened and the fine concavo-convex shape 7 is maintained.

The decorative sheet 2 is placed between the molding dies 8 using a decorative sheet 2 feeding device or the like, and fixed by means such as a clamp.

After the molding die 8 is closed, molten resin is injected and filled from the gate 9 into the molding die 8 to form the molding resin 10, and at the same time, the decorative sheet 2 is adhered to the surface thereof (FIG. 6). reference).

As the molten resin, polystyrene resin,
A general-purpose resin such as a polyolefin resin, acrylonitrile / butadiene / styrene resin, acrylonitrile / styrene resin, or acrylonitrile resin can be used. When the decorative member 1 is a key member, vinyl chloride-vinyl acetate copolymer resin, acrylic resin, and polycarbonate resin are preferable because they have excellent heat resistance, impact resistance, and transparency. In addition, depending on the use of the decorative member 1,
If necessary, it may be colored so as to have either a light shielding property or a light transmitting property.

After the molding resin 10 is solidified and the mold is opened (see FIG. 7), the decorative member 1 in which the decorative sheet 2 and the molding resin 10 are integrated can be obtained (see FIG. 1).

In the present invention, even in the step of injecting molten resin into the molding die 8 to integrate the fine concavo-convex shape 7 formed on the base sheet 3 by the preforming die 6 with the decorative sheet 2, Since the surface of the sheet 3 is not softened, the fine concavo-convex shape 7 formed by preforming can be maintained regardless of the surface shape of the cavity surface of the molding die 8. Therefore, it is possible to obtain the decorative member 1 having the fine concavo-convex shape 7 provided on the surface of the preforming die 6.

[0039]

Example 1 A polycarbonate film having a thickness of 130 μm is used as a base sheet, a thermosetting anchor layer made of an acrylic polyol resin is formed on the base sheet, and aluminum is vapor-deposited on the entire surface to form a metal thin film layer. Then, a black urethane two-component curable ink (SG410 manufactured by Seiko Advance Co., Ltd.) was partially formed as a decorative layer by a screen printing method, and then formed at 80 ° C. for 5 minutes.
After performing hot air drying for 5 minutes, dip it in an alkaline solution to remove the metal thin film layer where the decorative layer is not laminated, and then screen print the adhesive layer consisting of vinyl chloride-vinyl acetate copolymer resin. Was formed on the entire surface by and dried at 80 ° C. for 2 hours to obtain a decorative sheet.

Next, the decorative sheet is preheated by a high-pressure molding method so that the surface temperature becomes 130 ° C., and then the base sheet surface of the decorative sheet is partially recessed in which fine matt irregularities are formed. Pressure 1 along the preform of the shape
It was preformed at 2.0 MPa.

Next, the decorative sheet is placed in a molding die having a cavity shape corresponding to the three-dimensional shape, and a polycarbonate resin (Makrolon 2 manufactured by Bayer Co., Ltd.
205) was melted, injected, and cooled and solidified to obtain a decorative member in which the decorative sheet was integrated on the surface.

The decorative member thus obtained is one in which fine matte irregularities having a matte shape are partially formed, and the matte portion has a metallic luster and is excellent in matte feeling. There was a metallic luster pattern with a calm atmosphere.

Example 2 A decorative sheet was obtained in the same manner as in Example 1 except that a 125 μm thick polycarbonate-polybutylene terephthalate alloy film was used as the base sheet.

Next, the decorative sheet is preheated by a high-pressure molding method so that the surface temperature becomes 130 ° C., and the base sheet surface of the decorative sheet is then preformed into a concave shape in which hairline-shaped fine irregularities are formed. Pressure 10.0 along the mold
Preformed with Mpa.

Then, in the same manner as in Example 1, a decorative member having a surface integrated with the decorative sheet was obtained.

The decorative member thus obtained had fine hairline-shaped irregularities formed thereon and had an excellent metallic luster pattern of stainless steel.

Example 3 A polycarbonate film having a thickness of 130 μm was used as a base sheet, and a two-component urethane curable ink (SG410 manufactured by Seiko Advance Co., Ltd.) was used as a decorative layer on the base sheet to form a silver metallic colored layer by a screen printing method. And was dried at 80 ° C. for 2 hours to obtain a decorative sheet.

Next, the decorative sheet is preheated by a high-pressure molding method so that the surface temperature becomes 130 ° C., and then the base sheet surface of the decorative sheet is partially roughened with fine irregularities and smooth portions formed on the surface. Was preformed at a pressure of 10.0 Mpa so as to follow the surface of the preforming mold.

Then, in the same manner as in Example 1, a decorative member having a surface integrated with the decorative sheet was obtained.

The thus-obtained decorative member has fine irregularities and smooth portions formed on the surface, and the matte portion has a metallic luster and is excellent in matte feeling. It had a metallic luster pattern with a calm atmosphere.

[0051]

Since the present invention is constructed as described above, it has the following effects.

In the method for producing a decorative member of the present invention, a single layer film selected from a polycarbonate resin, a polycarbonate-polyethylene terephthalate alloy resin or a polycarbonate-polybutylene terephthalate alloy resin, or the above single layer film is used. Installed so that the base sheet side of the heat-softened decorative sheet consisting of at least the base sheet made of a multilayer film laminated on the outermost surface side and the decorative layer faces the preforming mold having the fine uneven shape. Then, the decorative sheet was preformed along the surface of the preforming mold, and the decorative sheet was placed in a molding die and the molten resin was injected to integrate the decorative sheet and the molten resin. Therefore, it is possible to easily obtain a decorative member having an arbitrary fine uneven shape.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a decorative member obtained by the method for manufacturing a decorative member of the present invention.

FIG. 2 is a cross-sectional view showing a step in the method for manufacturing a decorative member of the present invention.

FIG. 3 is a cross-sectional view showing a step of the method for manufacturing a decorative member of the present invention.

FIG. 4 is a cross-sectional view showing a step in the method for manufacturing a decorative member of the present invention.

FIG. 5 is a cross-sectional view showing a step of the method for manufacturing a decorative member of the present invention.

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

FIG. 7 is a cross-sectional view showing a step of the method for manufacturing a decorative member of the present invention.

[Explanation of symbols]

1 decorative member 2 decorative sheet 3 Base sheet 4 decorative layers 5 Adhesive layer 6 Preforming mold 7 Fine uneven shape 8 Mold 9 gates 10 Molding resin

Front page continuation (51) Int.Cl. ⁷ Identification code FI theme code (reference) // B29L 9:00 BB29L 9:00 F term (reference) 4F100 AB10 AK01C AK15G AK22G AK42B AK45B AL01G AL05B BA03 BA07 BA10A BA10C CB00 DD07A EC181 EH362 EH461 EH661 GB41 HB00A HB31 JN24 JN26 4F206 AA24K AA25K AA28 AA28K AD05 AD09 AD20 AD24 AF01 AG03 AH17 AH41 AH42 JA07 JB13 JB19 JF05 JF35 JL02 4F209 AA28 AG05 PA02 PB01 PC05 PG05 PW41 4F213 AA24 AA25 AA26 AA28 AC01 AD05 AD08 AF00 AG03 AH17 AH33 WA05 WA15 WA43 WA53 WA60 WB01 WC01 WE02 WE06 WF01 WF05 WF37 WK01 WK03 WW01 WW06 WW15

Claims (2)

[Claims] 1. A single layer film selected from any of a polycarbonate resin, a polycarbonate-polyethylene terephthalate alloy resin or a polycarbonate-polybutylene terephthalate alloy resin, or a multi-layer in which the single layer film is laminated on the outermost surface side. The base sheet side of the heat-softened decorative sheet comprising at least a base sheet made of a film and a decorative layer is placed so as to face a preforming mold having a fine uneven shape, and then the decorative sheet is preformed. Pre-form along the surface,
Next, the decorative sheet is placed in a molding die, and the molten resin is injected to integrate the decorative sheet and the molten resin, which is a method for manufacturing a decorative member. 2. The method for producing a decorative member according to claim 1, wherein the fine asperity shape of the preforming die is partially formed.