JP2003334827A - Resin film and method for manufacturing resin molding using the film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a crimp transferring resin film which is excellent in crimp transfer properties and stable in size when reused and controls the occurrence of wrinkles when reused and a method for manufacturing a resin molding by using the resin film. <P>SOLUTION: The resin film 20 is composed of a first film layer 21 on which a three-dimensional design 21a is formed and a second film layer 22 which is laminated on the back of the first film layer and is softer and thicker than the first film layer. During the molding of the resin molding, the molding surface of a mold 52 is covered with the back of the second film layer 22. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin film for grain transfer and a method for producing a resin molded product using the same.

[0002]

2. Description of the Related Art One of resin molded products is an automobile interior part, which includes an instrumental panel (hereinafter referred to as "instrument panel"), a console, a door trim, a pillar garnish and the like. Many automobile interior parts are composed of a core material (also referred to as "base material") for obtaining strength and a skin material for obtaining a design effect.

The base material and the skin material have been conventionally manufactured by various materials and methods, and one of them is a skin-integral type made of thermosetting urethane. For example, Japanese Patent Application Laid-Open No. 2
In the method of manufacturing an interior part shown in Japanese Patent Publication No. 000-351351 (hereinafter referred to as "conventional example 1"), a base material 101 is attached to an upper mold 100 as shown in FIG. The spray gun 10 along the inner mold surface of the lower mold 102
3 is moved to apply liquid urethane 104. next,
As shown in (c), the upper mold 100 is closed with respect to the lower mold 102 and the liquid urethane 104 is cured to integrate the skin material 106 on one surface of the base material 101. that time,
The unevenness (not shown) for grain of the lower die 102 is transferred to the surface of the skin material 106 to form a grain (not shown). Finally, as shown in (d), the upper mold 100 is opened with respect to the lower mold 102, and the interior part 108 integrated with the skin is taken out.

However, in the first conventional example, fine lines or fine irregularities other than grain may be formed on the surface of the skin material 106. That is, when molding a resin molded product having an undercut portion, the die includes a plurality of die members such as a slide core other than the lower die 102 and the upper die 100, and these die surface portions define the undercut formation portion. . Therefore, a gap is easily formed between the adjacent mold members, and when the resin material that has entered the gap is solidified, a thin separation line is formed on the surface of the resin molded product.

Further, the textured unevenness of the lower die 102 is formed by etching or the like. During this etching, fine unevenness due to corrosion may be formed in addition to the textured unevenness. As a result, when the wrinkles are transferred, the fine unevenness is also transferred to the skin material 106 to form fine unevenness, and the original wrinkles may be unclear.

In order to prevent the formation of fine irregularities other than grain, for example, in Japanese Patent Laid-Open No. 2000-263601 (hereinafter referred to as "conventional example 2"), an intracavity film is arranged between a pair of molds 110 and 115. is doing. That is, FIG.
As shown in (a), a film 113 is arranged on the front surface of the mold 110 on which the textured unevenness 111 is formed, and one mold 115 is closed with respect to the other mold 110. In this state, as shown in FIG. 10 (b), when the resin material 116 is injected into the cavity, the film 113 is pressed against the embossed irregularities 111 of the mold 110. Along with this, the resin material 11
6 enters into the unevenness for grain 111 with the film 113. As a result, after the resin material 116 is solidified, the molds 110 and 1
When 15 is opened and the resin molded product 120 is taken out, the grain 121 is transferred to the surface of the resin molded product 120.

Here, due to the action of the film 113, the resin material does not enter into the fine irregularities. This allows
It is possible to prevent the fine unevenness existing on the surface of the mold 110 from being transferred to the resin molded product 120. The film 113 is reused at the time of molding the next resin molded product 120.

[0008]

However, the above-mentioned conventional example 2
Has been found to have room for improvement. As in the second conventional example, the film 113 for transferring the textured irregularities 111 of the mold 110 onto the skin material is roughly classified into the following three characteristics.

The first requirement is that the transferability of grain is good. At the time of molding, the wrinkle irregularities 111 of the die 110 are transferred to the surface of the skin material through the film 113 to form a wrinkle pattern. Therefore, the unevenness 111 for the texture is formed on the film 1.
13 is transferred (the unevenness is formed on the film 113),
It is necessary that the unevenness of the film 113 is faithfully transferred to the skin material.

The second requirement is that the dimensions are stable upon reuse. After finishing the previous molding, film 1
13 is peeled off from the resin molded product 120, and the mold 110 is removed again.
And 115. Thus, the film 11
3 is pulled when it is peeled off, and is kept at a relatively high temperature during molding and at a relatively low temperature during attachment / detachment to / from the mold.
As a result, the dimensions (length, width, thickness) may change during repeated molding. When the dimensions of the film 113 change, it becomes difficult to follow the mold 110 and wrinkles occur, and the shape and size of the unevenness also change, making it difficult to transfer a predetermined grain pattern to the skin material.

The third requirement is that creases are unlikely to occur during reuse. After the previous molding is completed, the film 113 is peeled from the resin molded product 120, and the mold 11 is re-molded.
It is set in 0 and 115. When the film 113 is peeled from the resin molded product 120 for reuse, a specific portion of the film 113 is bent, and when the film 113 is set in the mold 110 for reuse, the specific portion is bent, which causes creases. easy. Film 11 with creases
When molding is performed using No. 3, thin lines other than grain are formed on the surface of the skin material.

The present invention has been made in view of the above-mentioned circumstances, and has a good transfer property of embosses, a stable size when reused, and a wrinkle transfer resin film in which creases are less likely to occur during reuse, and It is an object to provide a method for producing (molding) a resin molded product using this resin film.

[0013]

The inventor of the present application has paid attention to the relationship between the above first to third requirements and the hardness of the resin film. As a result, the resin film has the first requirement and the second requirement.
Is relatively hard to meet the requirements of
It has been found that relatively soft is desirable to meet the third requirement. That is, when a hard resin film is used, the first and second requirements are satisfied to some extent, but the third requirement is difficult to meet. On the other hand, when the soft resin film is used, the third requirement is satisfied to some extent, but the first and second requirements are difficult to satisfy. Then, in order to obtain ideal hardness, it was conceived to construct the resin film with two resin film layers having different hardness and thickness.

As described in claim 1, the embossed transfer resin film of the present invention is laminated on the back surface of the first film layer having the first hardness and the first thickness and the first thickness, and the back surface of the first film layer. And a second film layer having a second hardness lower than the first hardness and a second thickness thicker than the first thickness, and when the resin molded product is molded, the back surface of the second film layer is the mold surface of the mold. It is characterized by being covered.

In this resin film, the first film layer contributes to the transferability of the grain and the dimensional stability during reuse, and the second film layer
The film layer contributes to crease resistance when reused.

A resin film according to a second aspect is the resin film according to the first aspect, wherein the first film layer and the second film layer are made of an olefin resin. According to this resin film, high developability during vacuum molding and excellent releasability from the mold after molding can be obtained.

A resin film according to a third aspect is the resin film according to the second aspect, wherein the olefin resin includes a TPO resin, a PP resin and a PE resin. According to this resin film, the above three characteristics can be obtained in an optimal combination by adjusting the content of each resin.

A resin film according to a fourth aspect is the resin film according to the second or third aspect, wherein the first hardness of the first film layer is a Shore A hardness of 85 to 99 and a first thickness of 0.2 to 0. It is 5 mm. With this resin film, excellent grain transferability and dimensional stability during reuse can be obtained.

The resin film according to claim 5 is the resin film according to claim 2 or 3, wherein the second hardness of the second film layer is a Shore A hardness of 50 to 80 and a second thickness of 0.3 to 1. It is 0 mm. With this resin film, excellent crease resistance is obtained.

The resin film according to claim 6 has the 50% modulus value of 2.5 to 9.0 MPa and the thickness of 0.5 to 1.5 mm. According to this resin film, it is possible to obtain a resin film which is excellent in the transferability of the texture, the dimensional stability upon reuse, and the crease resistance upon reuse.

The method for producing (molding) a resin molded article having a design surface according to the present invention is, as described in claim 7, that a three-dimensional design is applied and a first film layer having a first hardness and a first thickness. First
A preparatory step of preparing a resin film joined to the back surface of the resin film layer and comprising a second film layer having a second hardness lower than the first hardness and a second thickness thicker than the first thickness; A placing step in which one die is placed so that the film layer covers the die surface; and a resin material is injected into a cavity between one die and the other die and cured to form a resin film. And a peeling step of peeling the resin film from the resin molded product.

According to this manufacturing method, a resin film having excellent transferability of grain and dimensional stability upon reuse and crease resistance upon reuse can be obtained in the preparation step. The resin film is placed in a mold in the placing step, and a resin material is injected into the cavity in the forming step to form a resin molded product, and the resin film is in close contact with the surface thereof. By peeling the resin film from the resin molded product in the peeling process,
A desired resin molded product is obtained.

The manufacturing method according to claim 8 is the manufacturing method according to claim 7, wherein the resin film has a three-dimensional design on the first film layer and has a shape corresponding to the mold surface of one mold. According to this manufacturing method, the resin film exactly fits the mold surface, and the three-dimensional design is transferred to the surface of the resin molded product.

A manufacturing method according to a ninth aspect is the manufacturing method according to the eighth aspect, wherein the resin-formed product has an undercut portion, and the undercut forming portion of the mold forming the undercut portion is a mold of a plurality of mold members. The resin film covers the mold surface portion by being divided by the surface portion. According to this manufacturing method, the resin film prevents the resin material from entering the gaps between the plurality of mold members.

The manufacturing method according to claim 10 is the method according to claim 8.
In the above, a base material is attached to the other die, and the foamable resin material is integrated with the cured foam to form a resin molded product. According to this manufacturing method, the strength of the resin molded product is improved by the base material integrated with the foam.

The manufacturing method according to claim 11 is the method according to claim 7.
In the above, the step of applying a coating material to the first film layer is included before the step of placing. According to this manufacturing method, the surface of the resin molded product is colored in a predetermined color with the coating material applied to the resin film.

The manufacturing method according to claim 12 is the method according to claim 1.
In No. 1, the resin film is coated with the coating material on the first film layer in a state where the resin film is turned upside down as compared with the time of placing in the placing step. According to this manufacturing method, the coating material can be easily applied to the resin film having a complicated shape.

The manufacturing method according to claim 13 is the method according to claim 7.
In, the method includes a coating step of coating the resin film after the peeling step. According to this manufacturing method, the coating material can be easily applied to the resin film.

The manufacturing method according to claim 14 is the method according to claim 7.
In addition, the method further includes a repeating step of repeating the placing step, the molding step and the peeling step at least once using the resin film peeled in the peeling step. According to this manufacturing method, the repeated use of the resin film reduces the manufacturing cost of the resin molded product.

[0030]

BEST MODE FOR CARRYING OUT THE INVENTION A Resin Film <Resin Film> (Composition (Constitution)) Both the first film layer and the second film layer constituting the resin film are made of an olefin resin. As olefin resin, TPO, PP, PE and EPR
Etc. The thickness of the resin film is 0.5 to 1.
It is 5 mm. If the thickness is less than 0.5 mm, the developability during vacuum forming, the texture transfer property, and the dimensional stability during reuse are poor, and if the thickness is greater than 1.5 mm, the handleability is poor. (Physical properties) The resin film is composed of two film layers having different hardnesses, and the first film layer on the front surface side and the second film layer on the back surface side have different hardnesses. Therefore, the unique hardness cannot be specified. Instead, the 50% modulus value is 2.5
To 9.0 MPa.

"50% modulus value" means JISK6
According to the tensile test method of 301 (dumbbell No. 3 type), when the sample was stretched in the TD direction (direction perpendicular to the continuous direction of the resin film) to 150% of the original length, the tensile stress acting on the sample That is.

The 50% modulus value corresponds to the hardness. The higher the hardness (harder), the larger the value, and the lower (softer) the smaller the value. Hardness is mainly related to grain transferability and reusability, and is slightly related to crease resistance.
It is also related to the developability during vacuum forming and the conformability to the surface shape of the mold. 50% modulus value is 2.5M
If it is less than Pa, the spreadability during vacuum forming, the texture transferability, and the dimensional stability during reuse will deteriorate, resulting in 9.0MP.
If it is larger than a, the crease resistance becomes poor. (Manufacturing Method) The resin film is obtained by laminating the first film layer and the second film layer, which are individually manufactured, by thermal lamination, and the second or first film manufactured previously while manufacturing the first or second film layer. It is produced by laminating the layers or by simultaneously producing and laminating the first film layer and the second film layer. Specific methods include a calendar method and a T-die extrusion method. (Function and Effect) Texture Transferability The term “texture transferability” refers to the transferability of the texture unevenness of the mold on the resin film during vacuum forming. The grain transferability is mainly related to the hardness or the 50% modulus value, and the higher the hardness, the more the grain transferability is improved. How to use For the resin film, when molding a resin molded product, the second film layer side with a low hardness and a large thickness is covered on the mold surface of the mold, and the first film layer side with a high hardness and a thin thickness is a resin molded product. To be in close contact. In that case, it can be curved so that the second film layer side is a convex surface and the first film layer side is a concave surface. After molding the reused resin molded product, the resin film is peeled off from the resin molded product. The olefin-based resin has excellent releasability from many resin materials that form a base material such as urethane foam. This resin film can be reused for the next molding, in which case creases and the number of times of use become problems. Wrinkle resistance,
The number of times of repeated use is related to the hardness or the 50% modulus value, and the lower the hardness of the crease resistance, the more difficult it is to crease. With respect to the number of times of repeated use, the higher the hardness, the more the dimensional stability increases, and the number of times of repeated use increases. <First Film Layer> (Material, Configuration) The first film layer is made of the first TPO resin, PP.
It consists of resin and PE resin. First TPO Resin The first TPO resin contains a partially crosslinked thermoplastic elastomer composed of ethylene-α-olefin copolymer rubber, thermoplastic olefin resin, process oil and the like. As shown in Table 1, the physical properties of the first TPO resin are as follows: Shore A hardness 70 to 99, MFR (Melting Flow Rat).
e) is 5 to 80 (230 ° C / 10kgf). Content is 50
To 90 parts by weight. PP resin PP resin includes homo PP, block PP and random PP.
Etc. is a thermoplastic olefin resin containing propylene as a main component. In addition, copolymer resins and elastomers with ethylene, α-olefins having 4 to 10 carbon atoms, and other monomers capable of copolymerizing with propylene (for example, vinyl acetate, acrylic acid ester, methacrylic acid ester, etc.) are also included.
As shown in Table 1, the physical properties of PP resin include Rockwell hardness of R60 to R110 and MFR of 0.3 to 10 (23
It is 0 ℃ / 2.16kgf). The content is 0 to 30 parts by weight. PE resin PE resin is LDPE, L-LDPE, HDPE, etc.
It is a thermoplastic olefin resin whose main component is ethylene. In addition, propylene, α-olefins having 4 to 10 carbon atoms, other monomers copolymerizable with ethylene (for example,
Copolymer resins with vinyl acetate, acrylic acid ester, methacrylic acid ester, etc.) and elastomers are also included. Table 1
As shown in, the PE resin has a Shore D hardness of 20.
To 70, MFR 0.2 to 10 (190 ℃ / 2.16kgf)
Is. The content is 0 to 40 parts by weight.

The first film layer may further contain an antioxidant and other stabilizers, a lubricant for improving releasability, a coloring agent (pigment master patch), etc., if necessary. Thickness The thickness of the first resin film layer is 0.2 to 0.5 mm. When the thickness is less than 0.2 mm, the texture transfer property and the dimensional stability during reuse are deteriorated, and when the thickness is more than 0.5 mm, the crease resistance is deteriorated.

[0034]

[Table 1]

(Physical Properties) The hardness of the first film layer is Shore A.
The hardness is 85 to 99. The 50% modulus value corresponding to hardness is 5.0 to 10.0 MPa. Shore A
When the hardness is less than 85, the texture transfer property and the dimensional stability upon reuse are deteriorated, and when the hardness is greater than 99, the crease resistance is deteriorated. (Function and Effect) The first film layer is located on the side covered with the die surface of the vacuum forming die, and the texture (three-dimensional design) is transferred.
Therefore, it is effective that the hardness is high in terms of the texture transfer property and the dimensional stability during reuse. Further, a thin thickness is effective in reducing the hardness of the entire resin film. If the thickness is too large, the hardness is too high and the crease resistance upon reuse is reduced. <Second Film Layer> (Material and Configuration) The second film layer is made of the first TPO resin and the second
It consists of TPO resin, PP resin and PE resin. First TPO Resin The composition of the first TPO resin is the first TP of the first film layer.
It is similar to O resin. The physical properties are as shown in Table 2.
It is the same as the first TPO resin of the first film layer. However, the content is 0 to 30 parts by weight. Second TPO Resin Like the first TPO resin, the second TPO resin contains a partially crosslinked thermoplastic elastomer composed of an ethylene-α-olefin copolymer rubber, a thermoplastic olefin resin, process oil and the like. However, the content of each component is different from that of the first TPO resin. As a result, as shown in Table 2, the physical properties of the second TPO resin are a Shore A hardness of 40 to 60 and an MFR of 5 to 80 (230 ° C./10 kgf). However, the content is 40 to 90 parts by weight. PP resin, PE resin PP resin is the same as the PP resin of the first film layer,
Its physical properties are the same as those of the PP resin as shown in Table 2. However, the content is 0 to 20 parts by weight. The PE resin is the same as the PE resin of the first film layer, and the physical properties thereof are the same as the PE resin as shown in Table 2. However, the content is 0 to 30 parts by weight.

The second film layer may further contain an antioxidant and other stabilizers, a lubricant for improving releasability, a colorant (pigment master patch) and the like. Thickness The thickness of the second film layer is 0.3 to 1.0 mm. If the thickness is less than 0.3 mm, the crease resistance is deteriorated, and if it is more than 1.0 mm, the wrinkle transfer property and the reusability are deteriorated.

[0037]

[Table 2]

(Physical Properties) The hardness of the second film layer is a Shore A hardness of 50 to 80. The 50% modulus value in the tensile test is 2.0 to 4.5 MPa. (Function and Effect) The second film layer is located on the side covered with the mold during molding. Therefore, it is effective that the hardness is low and the thickness is large from the viewpoint of improving the crease resistance during repeated use. B Molding Method A method for manufacturing a resin molded product includes a preparation step, a placing step, a molding step, and a peeling step. Furthermore, a painting process and a repeating process can be included. <Preparation Step> In the preparation step, the three-dimensionally designed first film layer having the first hardness and the first thickness and the back surface of the first film layer are bonded to each other, and the second film layer having the second hardness lower than the first hardness is used. A resin film including a second film layer having a second thickness greater than one thickness is prepared. The resin film has already been described in detail. <Placement Step> In the placement step, the resin film having the three-dimensional design on the surface of the first film layer is placed on one of the pair of molds so that the second film layer covers the mold surface.

The resin film may cover the entire mold surface or only a part thereof. When a fluid material such as liquid urethane is used as the resin material, it is desirable to cover the entire mold surface with a resin film in consideration of the sealing property. When one of the molds has a mold surface portion that defines the undercut forming portion, at least the mold surface portion is covered with the resin film.

The resin film before being placed may have a flat plate shape or may have a shape corresponding to the shape of the mold surface of one mold in advance. The flat resin film is brought into close contact with the mold surface when the molding process is performed. The shape corresponding to the die surface is formed by the vacuum forming die in the above-mentioned preparation step. that time,
It can be curved so that the second film layer side is convex and the first film layer side is concave. <Molding process> In the molding process, one mold (for example, lower mold)
Cover the mold surface with a resin film. After that, the foamable resin material is injected into the cavity defined by the pair of molds and cured to form a foam. Urethane or olefin can be used as the resin material. For example, if an integral skin foam material is used, a foam having a highly foamed core portion and a low foamed skin portion is formed.

A resin film is adhered to the skin,
The grain formed on the first film layer is faithfully transferred to the skin portion as grain.

The core material may be set in the other of the pair of molds (for example, the upper mold). The core material is made of ASG, PP, a mixture of PC and ABS, hard urethane or the like, and these can be subjected to flame treatment, primer treatment and the like. In this case, the core material and the foam are integrated. <Peeling Step> In the peeling step, the resin film is peeled from the cured skin material. As a result, the resin molded product is completed. <Applying Step> The present invention can further include an applying step of applying a paint of a predetermined color to the design surface of the resin molded product.
The paint can be transferred from the resin film. In this case, the coating film previously applied to the surface of the resin film first film layer is left on the surface of the resin molded product during molding.

The resin molded product has a convex shape (in this case,
The mold surface of the mold and the resin film have a concave shape.) When the convex surface has an undercut portion, the resin film can be turned upside down when the coating material is applied. If the first film layer side has a concave shape, it is difficult to apply the paint, so that the shape is inverted to form a convex shape. By doing so, it becomes easy to apply a predetermined color to the design surface of the resin molded product.

The paint may be applied after the resin film is peeled off from the resin molded product. In this case, the resin molding may be applied to a resin molded product from which the resin film has been peeled off with a spray gun or the like, and the application operation is simple. <Repeating Step> The present invention may further include a repeating step in which the cutting step, the molding step and the peeling step are repeated at least once. In the repeating process, the resin film used in the placing process and the molding process and peeled from the molded product in the peeling process can be reused, which reduces the manufacturing cost of the resin molded product.

[0045]

Embodiments of the present invention will be described below with reference to the accompanying drawings. (Resin molded product) A resin molded product is an instrument panel which is one of interior parts for automobiles. As shown in FIGS. 5 and 6, the longitudinal section of the instrument panel 10 has a linear intermediate portion 11a.
And a curved left end 11b and right end 11c.
A cross section in the thickness direction is composed of a core material 12 and an integral skin foam material (skin material) 15 integrated on one surface thereof.

The core material 12 is made of ASG (glass reinforcer of acrytonitrile styrene copolymer). The molding density of the integral skin foam material 15 is about 0.5 g / cm.
^3, which is composed of a highly foamed and thick core portion 17 and a low foamed and thin skin portion 19. The surface skin portion 19 has a texture (not shown) as a three-dimensional design.

The instrument panel 10 is die-cut in the X direction during molding, and the width becomes narrower toward the front of the left end portion 11b and the right end portion 11c as it goes forward in the drawing direction.
There are 8a and 18b. (Resin Film of Example) As shown in FIG. 1, a resin film (TPO film) 20 of this example is composed of two film layers 21 and 22. The first film layer 21 is provided with the embossed concave portion 21a and has a first hardness and a first thickness. The second film layer 22 is laminated on the back surface of the first film layer 21, and has a second hardness lower than the first hardness and a second thickness thicker than the first thickness.

More specifically, as shown in Table 3, the first film layer 21 comprises a first TPO resin, a PP resin and a PE resin. The content is 65 parts by weight of the first TPO resin, P
The P resin is 10 parts by weight and the PE resin is 25 parts by weight. The thickness is 0.3 mm.

As shown in Table 3, the second film layer 22 includes a first TPO resin, a second TPO resin, a PP resin, and a P resin.
It consists of E resin. The content is 10 parts by weight of the first TPO resin, 65 parts by weight of the second TPO resin, 5 parts by weight of the PP resin, and 20 parts by weight of the PE resin. The thickness is 0.7 mm. As a result, the physical properties of the resin film 20 are, as shown in Table 3, a 50% modulus value of 3.8 MPa, a tensile strength of 9.6 MPa, an elongation of 675%, and a tear strength of 4%.
It is 34 N / cm. The thickness is 1.0 mm.

The physical properties were measured according to JIS K6301. The Shore A hardness was measured by stacking five sample sheets. The 50% modulus value was measured with dumbbell type 3. The tensile test was performed using a dumbbell No. 3 model. The tear test was performed using a tear type B at a measurement speed of 200 mm / min, and was measured in the TD direction of the sample sheet. (Resin Film of Comparative Example) Comparative Examples 1 to 4 consisting of a single layer
The resin film of was prepared. As shown in Table 3, the first comparative example includes 10 parts by weight of the first TPO resin and 65 parts by weight of the second TPO resin.
TPO resin, 5 parts by weight PP resin and 20 parts by weight PE
Composed of resin. Shore A hardness is 76, 50% modulus is 2.7 MPa, tensile strength is 8.5 MPa, elongation is 7
09% and tear strength is 414 N / cm. The thickness is 1.
It is 0 mm.

The second comparative example comprises 50 parts by weight of the first TPO resin, 30 parts by weight of the second TPO resin, 5 parts by weight of the PP resin and 15 parts by weight of the PE resin. Shore A hardness is 8
4, 50% modulus value 3.8 MPa, tensile strength 9.2 MPa, elongation 685%, tear strength 516 N /
cm. The thickness is 1.0 mm.

The third comparative example comprises 65 parts by weight of the first TPO resin, 10 parts by weight of PP resin and 25 parts by weight of PE resin. Shore A hardness is 91, 50% modulus is 6.0 MPa, tensile strength is 12.6 MPa, elongation is 73
3%, tear strength is 713 N / cm. Thickness is 1.0
mm.

The fourth comparative example comprises 60 parts by weight of the first TPO resin, 20 parts by weight of PP resin and 20 parts by weight of PE resin. Shore A hardness is 95, 50% modulus is 8.0 MPa, tensile strength is 12.8 MPa, and elongation is 65.
8%, tear strength is 763 N / cm. Thickness is 1.0
mm.

[0054]

[Table 3]

(Manufacturing Method of First Embodiment) The above instrument panel 1
The manufacturing method of 0 will be described with reference to FIGS. 2, 3 and 4. Preparation Step The preparation step includes a vacuum forming step, a mold releasing step, a film inversion step, an in-mold coating step, and a film reinversion step.

In the vacuum forming step S1 shown in FIG. 2 (a),
The TPO film 20 is vacuum formed by the convex embossing mold 31.
The convex embossing die 31 has a convex portion (mold surface) 32, and a convex embossing (not shown) and protruding portions 33a and 33b are formed in a predetermined portion. The TPO film 20 is set such that the first film layer 21 faces the mold surface 32 of the convex embossing mold 31. When heated to 180 ° C. and evacuated, the TPO film 20 deforms following the shape of the mold surface 32.

Next, in the demolding step S2 shown in FIG. 2B, the TPO film 20 is peeled off from the convex embossing die 31. The TPO film 20 is provided with cover portions 24a and 24b protruding from the back surface (upper surface) 20b, and
The first film layer 21 on the front surface (lower surface) 20a side is provided with an embossed concave portion 21a.

In the film reversing step S3 shown in FIG. 2C, the front and back of the TPO film 20 are reversed. As a result, the TPO film 20 after the reversal becomes plane-symmetric with respect to the plane 1 and the TPO film 20 before the reversal, and the surface 20a that has been facing inward, that is, the first film layer 21 faces outward. Further, the cover portions 24a and 24b project symmetrically to those before the inversion.

Therefore, in the in-mold coating step S4 shown in FIG. 2 (d), a spray gun 35 is used to apply a paint of a predetermined color to the first film layer 21 that is convex outward. Next, the film re-inversion step S shown in FIG.
In 5, the front and back of the TPO film 20 are turned over again. As a result, the TPO film 20 after re-inversion has the same shape as the TPO film 20 of FIG. Placement Process In the film / insert setting process (placement process) S6 shown in FIG.
Open and mount the TPO film 20 in the recess of the foaming lower mold 52. As shown in FIG. 4, the lower foam mold 52 is a mold body 3
6, a pair of push-out members 39 and 42 fitted into the recesses 38a and 38b, and a pair of slide members (slide cores) 45 and 48 placed thereon. The TPO film 2 is formed on the inner surfaces of the mold body 36, the pushing members 39 and 42, and the slide members 45 and 48.
A mold inner surface 52a that matches the shape of the back surface 20b of 0 is formed.

That is, the die main body 36 has a curved surface 37a and flat surfaces 37b and 37c on the left and right sides thereof, and a recess 38a is formed at the boundary between the left flat surface 37b and the curved surface 37a, and the curved surface 37a is formed. A recess 38b is formed near the valley of 37a (near the flat surface on the right side).

The pushing member 3 on the left side is inserted into the depression 38a on the left side.
9 is fitted, and a projection 40b projects obliquely from the inclined surface 40a into the recess. As a result, the protrusion 40b and the inclined surface 46a of the slide member 45 form a recess 47 that opens obliquely upward to the right. The left slide member 45 is placed on the left flat surface 37b of the mold body 36 and the upper surface 40c of the left pushing member 39, and the inclined surface 40
It has an inner surface 46a that projects slightly inward from the recess a.

The mold body 36, the pushing member 39 and the slide member 45 are adjacent to each other to form an undercut forming portion. When the die is removed, the pushing member 39 on the left side is pushed upward (Y direction), and the sliding member 45 on the left side is slid (retracted) in the left direction (Z direction).

On the other hand, the upper half of the right pushing member 42 fitted in the right recess 38b projects upward into the recess. The right slide member 48 is placed on the right flat surface 37c of the die main body 36, and a protrusion 49 protruding leftward toward the pushing member 42 is formed. as a result,
The pushing member 42 and the projection 49 form a recess 50 that opens obliquely upward to the left.

The mold body 36, the pushing member 42 and the slide member 48 are adjacent to each other to form an undercut forming portion. The right pushing member 42 is pushed upward (Y direction) and the right sliding member 48 is slid (retracted) rightward (Z direction) during die cutting.

The TPO film 20 has the cover portions 24a and 24b fitted in the recesses 47 and 50, respectively,
The film layer 22 is brought into close contact with the mold inner surface 52a of the lower mold 52. Thereby, the mold body 36 and the left pushing member 39
And the gap between the left push-out member 39 and the slide member 45 are closed. Further, the gaps between the die main body 36 and the pushing member 42 and the slide member 48 on the right side are closed.

Next, the foaming upper mold 55 is closed, and in the integral foaming step (molding step) S7 shown in FIG. 3 (b), polyol 01FK15 and isocyanate 01FK16 manufactured by Sumika Bayer Urethane Co., Ltd. are mixed to form a core. Material 12 and TPO
It was injected into the cavity C between the film 20 and foamed to form the integral skin foam material 15. The in-mold curing time at this time was about 2 minutes, and the molding density of the integral skin foam material 15 was about 0.5 g / cm ³ .

As a result, a resin molded product was completed in which the TPO film 20, the integral skin foam material 15 having the core portion 17 and the skin portion 19, and the core material 12 were integrated. In addition, the first film layer 21 of the TPO film 20
The embossed concave portion 21a transferred to the surface was faithfully imprinted on the surface of the skin portion 19 as a convex embossing. Peeling step Finally, in the demolding / film separating step (peeling step) S8 shown in FIG. 3C, the integral skin foam material 15 and the TPO film 20 are separated from the foaming molds 52 and 55, and then the integral skin foam. The TPO film 20 is peeled off from the material 15. At that time, the TPO film 20 could be easily peeled off from the resin molded product, and no elongation occurred during the peeling. Further, the coating material applied to the first film layer 21 was peeled off from the TPO film 20 and remained on the skin side 19, and the surface of the skin portion 19 was colored in a predetermined color.

As a result, the integral skin foam material 15 including the core material 12, the core portion 17 and the skin portion 19 is formed.
A skin-integrated instrument panel 10 including and is manufactured. When manufacturing the instrument panel 10 after the second and subsequent repeating steps, an in-mold coating step S4, a film re-inversion step S5, a film / insert setting step S6, an integral foaming step S7, and a mold releasing step
The film separating step S8 is repeated. At that time, the front and back of the TPO film 20 separated from the resin molded product after molding are reversed and reused. After applying the coating material to the first film layer 21, the front and back are reversed again. (Effect of Resin Film of Example) The effect of the resin film of Example was evaluated by the texture transfer property of the resin film, the crease resistance and the number of times of repeated use, and the results are shown in Table 4.

As is clear from Table 4, the wrinkle transfer rate is O: 90%, the crease resistance is O, and the number of repeated uses is 30.
It was once. The "texture transfer rate" means a surface heating temperature of 18
Depth 80 of vacuum forming die 31 when vacuum forming at 0 ° C
It means the grain depth transfer rate from the convex grain of μm. "Folding wrinkle resistance" was evaluated based on the occurrence of wrinkling on the sheet after 30 times of repeated use. O means almost no creases, Δ means partial creases at several places, and X means many creases at all. The number of times of repeated use means the number of times until the dimension of the sample sheet is expanded at the time of peeling and there is a hindrance in setting in the next mold.

As is apparent from this, the TPO of the embodiment is
The sheet 20 has satisfactory wrinkle transfer rate, crease resistance, and number of times of repeated use.

(Resin Film of Comparative Example) Comparative Examples 1 to 4
An instrument panel was molded using the resin film of Example 1 and the molds 52 and 55 by the same procedure as that of the resin film of the example. Then, three characteristics were examined as in the example.
The results are shown in Table 4.

As is clear from the above, the wrinkle transfer rate of the resin film of Comparative Example 1 was 76% in x, the crease resistance was ◯, and the number of times of repeated use was 5 times. That is, the crease resistance is good, but the wrinkle transfer rate and the reusability are poor. It is considered that Comparative Example 1 has the same structure as the second film layer 22 of the Example and has too low hardness.

The grain transfer rate of the resin film of Comparative Example 2 was x.
Was 78%, the crease resistance was Δ, and the number of times of repeated use was 21 times. The wrinkle transfer rate, crease resistance, and number of times of repeated use were not satisfactory. It is considered that this is because the content of the second TPO resin having a higher hardness than that of the first comparative example was increased, but the increase in hardness was insufficient, resulting in a half-finished result.

The grain transfer rate of the resin film of Comparative Example 3 was O.
Was 92%, the crease resistance was x, and the number of times of repeated use was 35 times. The wrinkle transfer rate and the number of times of repeated use were satisfactory, but the crease resistance was not satisfactory. Comparative Example 3 has the same structure as the first film layer 21 of the Example after all, and the wrinkle transfer resistance of the resin film of Comparative Example 4, which is considered to be too high, is 87% and the wrinkle resistance is X, The number of times of repeated use was 36 times. The number of times of repeated use was satisfactory, but the wrinkle transfer rate and the crease resistance were not satisfactory.
Although the composition was slightly changed as compared with the third comparative example, it is considered that the composition was similar to that of the first film layer of the example, and the result was similar to that of the comparative example 3.

[0075]

[Table 4]

(Effect of Manufacturing Method of First Embodiment) According to the manufacturing method of the first embodiment, the undercut portions 18a and 18b are present in the instrument panel 10, but the molded skin portion 19 is divided. No separation is formed. A gap between the mold body 36 and the left push member 39 and the slide member 45, and a gap between the mold body 36 and the right push member 42 and the slide member 48.
Is a gap between the cover portions 24a and 24 of the TPO film 20.
This is because it is covered with b.

Further, at the time of manufacturing the instrument panel 10 after the second time, the TPO film 20 used at the time of the first time is manufactured.
Can be reused. Demolding / Film separation process S
The TPO film 20 separated from the molded product in 8 has the same shape as before being set in the foaming lower mold 52 in the film / insert setting step S6. That is, the resin film forms a part of the foaming lower mold 52.

Further, the coating material is surely applied to the cover portions 24a and 24b of the TPO film 20 having a complicated shape.
In the in-mold coating step S4, before applying the coating material to the first film layer 21 of the TPO film 20, TP
The front and back of the O film 20 are reversed. As a result of reversal, TPO
The film 20 has a convex shape as a whole. In other words,
This is because there is no deep or thin concave portion. (Manufacturing Method of Second Embodiment) A second embodiment of the manufacturing method of the present invention will be described with reference to FIGS. In the second embodiment, the shape of the undercut portion of the instrument panel is relatively simple, and the paint can be directly applied to the molded instrument panel.
Therefore, unlike the first embodiment, the step of reversing the film is not included. Other points are basically common to the first embodiment.

In the vacuum forming step S11 shown in FIG. 7A, the TPO film 60 is covered on the embossing die 70 having a convex embossing, and the concave embossing is formed on the first film layer 61 of the TPO film 60 by vacuum forming. The TPO film 60 is
In the demolding step S12 shown in FIG. 7B, the mold 70 is separated. In the film / insert setting step (cutting step) S13 shown in FIG. 7C, the core material 62 is attached to the convex portion of the foaming upper mold 72, and the TPO is fitted to the concave portion of the foaming lower mold 73.
Attach the film 60.

In the integral foaming step (molding step) S14 shown in FIG. 7D, an integral skin foam material is injected into the cavity between the core material 62 and the TPO film 60, and then foamed to form an integral skin. Foam material 64 was formed. This allows TPO film 60
A resin molded product 70 in which the integral skin foam material 64 including the core portion 17 and the skin portion 19 (see FIG. 3) and the core material 62 were integrated was obtained. Further, the concave wrinkles of the first film layer 61 of the TPO film 60 were transferred to the surface of the skin portion 19.

Next, in the demolding step S15 shown in FIG. 8A, the resin molded product 66 is taken out from the foaming lower mold 73.
The TPO film 60 is peeled from the integral skin foam material 64 and the core material 62 in the film separating step (peeling step) S16 shown in FIG. 8B, and is repeatedly used in the second and subsequent manufacturing of the instrument panel 10. .

In the trimming step S17 shown in FIG. 8C, the peripheral edge of the integro skin foam material 64 is trimmed. Then, the coating step S1 shown in FIG.
8, a predetermined paint is applied to the surface of the skin portion 19 by the spray gun 75, whereby the instrument panel 10 is manufactured. (Effect of Manufacturing Method of Second Embodiment) According to the manufacturing method of the second embodiment, in addition to the effect of the manufacturing method of the first embodiment,
The following effects can be obtained. Since there is no step of reversing the front and back of the TPO film 60, the manufacturing of the instrument panel 10 is simple and the manufacturing cost can be reduced. Further, the coating of the coating on the surface of the first film layer of the skin portion 19 is performed by the integral skin foam material 6
Since it is performed after the molding of No. 4, the coating work becomes easy.

[0083]

As described above, according to the resin film of the present invention and the method for producing a resin molded product using the resin film, since the wrinkle-forming portion of the resin film is difficult to collapse, the wrinkles are formed on the surface of the resin molded product. Faithfully transferred to a resin molded product with a beautiful design surface. Further, when the resin film is peeled from the resin molded product for reuse, it is difficult for creases to be formed, so that it is possible to prevent the formation of small lines or the like on the surface of the resin molded product during the next molding. Furthermore, when the resin film is reused, the dimensions are unlikely to change, so that it can be used repeatedly.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view showing an example of a resin film according to the present invention.

2 (a), (b), (c), (d) and (e) are explanatory views showing the first half of the method for producing a resin molded product according to the first embodiment of the present invention.

3 (a), (b) and (c) are explanatory views showing the latter half of the manufacturing method of the first embodiment.

FIG. 4 is a cross-sectional view of a foam lower mold used in the above manufacturing method.

FIG. 5 is a perspective view of an instrument panel manufactured by the above manufacturing method.

6 is a sectional view taken along line 6-6 of FIG.

7 (a), (b), (c) and (d) are explanatory views showing the first half of the method for producing a resin molded product according to the second embodiment of the present invention.

8 (a), (b), (c) and (d) correspond to the second
It is explanatory drawing which shows the latter half of the manufacturing method of an Example.

9 (a), (b), (c) and (d) are explanatory views for explaining a first conventional example.

10 (a), (b) and (c) are explanatory views for explaining a second conventional example.

[Explanation of symbols]

10: Interior parts 12: Core material 15: Integral skin foam material 19: Skin part 20: Resin film 21: 1st film layer 21a: Wrinkles for texture 22: 2nd film layer 36, 39, 42, 45, 48: Mold member 52: Lower mold 55: Upper mold

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B32B 7/02 101 B32B 7/02 101 // B60R 13/02 B60R 13/02 Z (72) Inventor Kawai Anken 1876 Higashimachi, Hamamatsu City, Shizuoka Prefecture Kyowa Leather Co., Ltd. F-term in the company (reference) YY00A YY00B 4F202 AA03 AF07 AH25 AH26 AJ09 CA01 CB01 CD02 CD22 CD30 CK32 4F204 AA03 AA04 AA11 AA42 AA45 AF07 AG03 AG05 AG20 AH25 AH26 AJ03 AJ09 EA01 EA04 EB01 EB11 EB22 EF51 EF05 EF05 EF05 EK

Claims (14)

[Claims] 1. A first film layer having a three-dimensional design and having a first hardness and a first thickness, and a back surface of the first film layer, the second hardness being lower than the first hardness and the first thickness being less than the first thickness. And a second film layer having a second thickness that is also thicker, and the back surface of the second film layer is covered with the mold surface of the mold during molding of the resin molded product. 2. The resin film according to claim 1, wherein the first film layer and the second film layer are made of an olefin resin. 3. The olefin resin is TPO resin, PP
The resin film according to claim 2, comprising a resin and a PE resin. 4. The first hardness of the first film layer is Shore A.
The resin film according to claim 2 or 3, wherein the hardness is 85 to 99, and the first thickness is 0.2 to 0.5 mm. 5. The second hardness of the second film layer is Shore A.
The resin film according to claim 2, wherein the hardness is 50 to 80, and the second thickness is 0.3 to 1.0 mm. 6. The resin film has a 50% modulus value of 2.5 to 9.0 MPa and a thickness of 0.5 to 1.5 m.
The resin film according to claim 4, which is m. 7. A method of manufacturing a resin molded product having a design surface, comprising a first film layer having a first hardness and a first thickness and a first thickness, and a first film layer bonded to the back surface of the first resin film layer. A preparatory step of preparing a resin film comprising a second film layer having a second hardness lower than 1 hardness and a second thickness thicker than the first thickness; and the resin film covering the mold surface with the second film layer. As described above, a placing step of placing the die on one die and a resin integrated with the resin film by injecting a resin material into a cavity between the die and the other die to cure the die. A method for producing a resin molded article, comprising: a molding step of molding a molded article; and a peeling step of peeling the resin film from the resin molded article. 8. The resin film in the preparing step has a shape corresponding to a mold surface of the one mold.
The method for producing a resin molded article according to. 9. The resin-formed product has an undercut portion on a design surface, and in the molding step, the undercut-formed portion of the mold is divided by mold surface portions of a plurality of mold members, and the resin film is The method for producing a resin molded product according to claim 7, which covers the mold surface portion. 10. The resin molding according to claim 8, wherein in the molding step, a base material is attached to the other mold, and the foamable resin material is integrated with a cured foam to form a resin molded article. Method of manufacturing goods. 11. The method for producing a resin molded product according to claim 7, further comprising a coating step of coating a coating material on the first film layer before the placing step. 12. The method for producing a resin molded product according to claim 11, wherein the resin film is coated with the coating material on the first film layer in a state where the resin film is turned upside down from that at the time of placing in the placing step. 13. The method for producing a resin molded article according to claim 7, further comprising a coating step of coating a coating material on the first film layer after the peeling step. 14. The resin molded article according to claim 7, further comprising a repeating step of repeating the placing step, the molding step and the peeling step at least once using the resin film peeled in the peeling step. Manufacturing method.