JP2005091650A - Molded product with convex lens by simultaneous molding and decorating, and method for manufacturing molded product with convex lens by simultaneous molding and decorating - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded product with a convex lens by simultaneous molding and decorating, the product having superior wear resistance and scratch resistance, and to provide a method for manufacturing the product. <P>SOLUTION: A transparent hard coat layer 4 is formed on the surface of a convex lens part 2 of a molded resin layer 15, and a decorative pattern layer 3 is formed on the face opposite to the face where the hard coat layer is formed. That is, a decorating sheet, having an unhardened or half-hardened transparent hard coat layer, is disposed in a (A) die of an injection molding die having a plurality of hemispheric recesses formed thereon, a decorating sheet having a decorative pattern layer is disposed in a (B) die of the injection molding die, a molding space is formed by fastening the (A) die and the (B) die, and a molding resin is injected into the molding space to form an injection molded product, as well as a transparent unhardened or semi-hardened hard coat layer and a decorative pattern layer on the surface of the injection molded product, and then the unhardened or semi-hardened layer is hardened. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The inventor of the present invention is a simultaneous decorative molding with a convex lens in which one surface of a transparent injection molded resin layer is composed of a plurality of hemispherical convex lens portions, and a decorative pattern is formed on the surface opposite to the convex lens portion surface of the injection molded resin layer Has filed a patent application (Japanese Patent Application No. 2003-281746) relating to a product and its manufacturing method.

  On the other hand, the molding simultaneous decorating method in which a decorative layer is provided on both sides as well as on one side of the molded resin layer as in Patent Document 1 is in the spotlight. In the case of such a molding simultaneous decorating method, the decorating sheet and the second decorating sheet are arranged in both the A mold and the B mold, and the molding resin is injected from the side gate. Is common.

JP-A-6-99457

  However, the above-mentioned molded simultaneous decorative molded product with a convex lens cannot be used in applications requiring wear resistance because the convex lens portion is made of a molded resin layer and the surface strength depends on the mechanical properties of the molded resin layer. There was a problem.

  Therefore, the present inventor has made the following invention in order to solve the above problems. That is, according to the first aspect of the present invention, one surface of the transparent injection-molded resin layer is composed of a plurality of substantially hemispherical convex lens portions, and a transparent hard coat layer is formed on the surface of the convex lens portion of the injection-molded resin layer, It is a molded simultaneous decorative molded product with a convex lens in which a decorative pattern layer is provided on the surface opposite to the hard coat layer forming surface of the molded resin layer.

  In the second aspect of the present invention, a decorative sheet provided with an uncured or semi-cured transparent hard coat layer is disposed on an A mold of an injection mold having a plurality of substantially hemispherical recesses. Then, a decorative sheet provided with a decorative pattern layer is arranged on the B mold of the injection mold, and the molding space is formed by closing the A mold and the B mold, and then the molding space Injecting a molding resin into an injection molded product and simultaneously forming an uncured or semi-cured transparent hard coat layer and a decorative pattern layer on the surface of the injection-molded product, and then uncured or semi-cured hard It is a method for producing a molded simultaneous decorative molded product with a convex lens, wherein the coat layer is cured.

  The molded simultaneous decorative molded product with a convex lens of the present invention has an effect of maintaining high wear resistance and scratch resistance because a transparent hard coat layer is formed on the surface of the convex lens portion. Further, according to the method for producing a molded simultaneous decorative molded product with a convex lens of the present invention, the hard coat layer can be provided simultaneously with the molding, and the simultaneous decorative molding with a convex lens having excellent wear resistance and scratch resistance. There exists an effect which can obtain a molded article easily.

  Hereinafter, with reference to the drawings, a molded simultaneous decorative molded product with a convex lens of the present invention and a manufacturing method thereof will be described. In the molded simultaneous decorative molded product 30 with a convex lens of the present invention, one surface of the transparent injection-molded resin layer 15 is composed of a plurality of substantially hemispherical convex lens portions 2, and is transparent on the surface of the convex lens portion 2 of the injection-molded resin layer 15. The hard coat layer 4 is formed, and the decorative pattern layer 3 is provided on the surface opposite to the hard coat layer 4 forming surface of the injection-molded resin layer 15 (see FIG. 1).

  The injection-molded resin layer 15 has a function of holding the decorative pattern 3 and functions to promote the lens effect generated by proper selection of the convex lens portion 2 and the decorative pattern 3.

  The material of the injection molded resin layer 15 is preferably a resin such as acrylic, polycarbonate, acrylonitrile butadiene styrene, acrylonitrile styrene, polystyrene, polyethylene, polypropylene, polyamide.

  The thickness of the injection molded resin layer 15 is preferably 0.8 mm to 2.5 mm. When the thickness of the injection molded product 15 is less than 0.8 mm, the injection molding itself is difficult and the strength of the injection molded product is weak. On the other hand, when the thickness of the injection molded product 15 exceeds 2.5 mm, molding defects such as sink marks are likely to occur.

  The convex lens portion 2 is formed on one surface of the injection-molded resin layer 15 and fulfills a function of causing a lens effect by proper selection with the decorative pattern layer 3 formed on the opposite surface.

  The diameter of the convex lens portion 2 is preferably 0.05 mm to 3.0 mm. It is technically difficult to produce an injection mold that can form a convex lens portion 2 of less than 0.05 mm. With a convex lens portion 2 of more than 3.0 mm, the lens effect cannot be obtained and the decorative pattern layer has a deep feeling. Because it is difficult to give.

  The height of the convex lens portion 2 is preferably 0.003 mm to 2.0 mm. It is technically difficult to manufacture an injection mold that can form a convex lens portion 2 of less than 0.003 mm. With a convex lens portion 2 of more than 2.0 mm, the lens effect cannot be obtained and the decorative pattern layer has a sense of depth. Because it is difficult to give.

  In the method of forming the convex lens portion 2, a plurality of substantially hemispherical concave portions 22 corresponding to a mold for forming the convex lens portion 2 are provided on the surface of the A mold 20 of the injection molding die, and the molding space portion 8 is formed. In this method, a transparent injection molding resin is filled and the convex lens portion 2 is formed on one side of the transparent injection molding resin layer 15.

  Examples of the method for forming the recess 22 include a method in which the surface of the A mold 20 of the injection mold is formed by etching or engraving, but is not particularly limited.

  The decorative pattern layer 3 is formed by a general-purpose printing technique or the like, which is a pattern made up of micropatterns such as letters, geometric patterns, and solid surfaces. A plurality of decorative pattern layers 3 may be formed in parallel. Further, the decorative pattern layer 3 may be provided with a metal film layer such as aluminum, chromium, copper, nickel, indium, tin, or silicon oxide by a method such as vacuum deposition or plating. In this case, the metal film layer may be entirely or patterned.

  Examples of the material of the decorative pattern layer 3 include polyester resins, acrylic resins, vinyl resins, nitrified cotton resins, urethane resins, and chlorinated rubber resins, but are not particularly limited.

  The thickness of the decorative pattern layer 3 is preferably 0.5 μm to 50 μm. When the film thickness is less than 0.5 μm, there is a problem that sufficient designability cannot be obtained, and when it is more than 50 μm, there is a problem that it is difficult to dry after printing. However, in the case of a metal film layer, 50 to 1200 mm is preferable. This is because when the film thickness is less than 50 mm, there is a problem that sufficient designability cannot be obtained, and when it is more than 1200 mm, there is a problem that cracks are likely to occur.

  As a method of forming the decorative pattern layer 3, the decorative sheet 10 is placed on the B mold 21 of the injection mold, the molding resin 9 is filled in the molding space 8 formed by the decorative sheet 10, By solidifying, the decorative sheet 10 and the molded resin layer 9 can be integrally bonded simultaneously with injection molding (see FIG. 2).

  The decorative sheet 10 may be an insert sheet integrated with the injection-molded resin layer 15 as shown in FIG. 3, or the release layer 5 is formed on the base sheet 1 as shown in FIG. 15 may be a transfer sheet that peels and removes the base sheet 1 after being integrated with the substrate 15.

  The hard coat layer 4 is formed on at least the surface of the convex lens portion 2 and functions to improve the wear resistance and scratch resistance of the surface of the convex lens portion 2. The material of the hard coat layer 4 is an ionizing radiation curable resin such as a cyanoacrylate resin or a urethane acrylate resin, a thermosetting resin such as an epoxy resin, a thermosetting acrylic resin, or a thermosetting urethane resin, And these cured and combined resins.

  The film thickness of the hard coat layer 4 is preferably 1.5 μm to 50 μm. This is because if the film thickness is less than 1.5 μm, there is a problem that sufficient abrasion resistance and scratch resistance cannot be obtained, and if it is more than 50 μm, there is a problem that it is difficult to dry after printing.

  As a method of forming the hard coat layer 4, the hard coat sheet 11 is placed on the B mold 21 of the injection mold, the molding space 8 formed by the hard coat sheet 11 is filled with the molding resin 9, By solidifying, a method of integrally bonding the hard coat sheet 11 and the molded resin layer 9 simultaneously with injection molding can be exemplified (see FIG. 2).

  The hard coat sheet 11 may be an insert sheet integrated with the injection molded resin layer 15 as shown in FIG. 5, or the release layer 5 is formed on the base sheet 1 as shown in FIG. 15 may be a transfer sheet that peels and removes the base sheet 1 after being integrated with the substrate 15.

  However, since the hard coat layer 4 is a very hard layer, it may not follow the curved surface of the convex lens portion 2 and may crack. Therefore, it is preferable that the hard coat layer 4 is formed on the hard coat sheet 11 in an uncured or semi-cured state, and the hard coat layer 4 is cured after being provided on the convex lens portion 2.

  The uncured or semi-cured state of the hard coat layer 4 refers to a state where the surface state of the original hard and tough physical properties has not been reached although the touch is dry. Such an uncured or semi-cured state can be obtained by adjusting the dose of ionizing radiation or the amount of heating to an amount that is only dry to the touch.

  The material of the base sheet 1 is preferably a polyester resin, a vinyl chloride resin, an acrylic resin, a polycarbonate resin, a polypropylene resin, a polyethylene resin, a polyurethane resin, a polystyrene resin, an acetate resin, a polyamide resin, or the like. .

  The film thickness of the base sheet 1 is preferably 5 μm to 5 mm. This is because if the film thickness is less than 5 μm, there is a problem that the sheet is not rigid and the convex lens part 2 cannot be supported, and if it is thicker than 5 mm, the sheet is too rigid and difficult to handle.

  The formation method of the base sheet 1 may be a general film forming method such as extrusion molding, calendar molding, or casting. In addition, the base sheet 1 may be subjected to easy adhesion treatment such as corona discharge treatment, plasma treatment, and easy adhesion primer coating on the surface on the side on which the printed layer is formed, if necessary.

  The release layer 5 is made of acrylic resin, vinyl chloride resin, polyurethane resin, polyester resin, polypropylene resin, polyethylene resin, polystyrene resin, polycarbonate resin, vinylon resin, acetate resin, polyamide. Resin may be mentioned, and a preferable material is appropriately selected according to the releasability with each layer.

  The thickness of the release layer 5 is preferably 0.5 μm to 50 μm. If the film thickness is less than 0.5 μm, there is a problem that sufficient peelability cannot be obtained, and if it is more than 50 μm, there is a problem that it is difficult to dry after printing.

  The method for forming the release layer 5 may be a method such as gravure printing, offset printing, or screen printing, or a method such as painting, dipping, or reverse coater.

  Further, an adhesive layer 6 may be provided on the decorative pattern layer 3 and the hard coat layer 4 in order to firmly bond the decorative pattern layer 3 and the hard coat layer 4 to the injection molding resin layer 15.

  The material of the adhesive layer 6 is acrylic resin, vinyl chloride resin, polyurethane resin, polyester resin, polypropylene resin, polyethylene resin, polystyrene resin, polycarbonate resin, vinylon resin, acetate resin, polyamide. Resin may be used, and a preferable material is appropriately selected according to the adhesion to each layer.

  The film thickness of the adhesive layer 6 is preferably 0.5 μm to 10 μm. If the film thickness is less than 0.5 μm, there is a problem that sufficient adhesion cannot be obtained, and if it is more than 10 μm, there is a problem that it is difficult to dry after printing.

  The method for forming the adhesive layer 6 may be a method such as gravure printing, offset printing, or screen printing, or a method such as painting, dipping, or reverse coater.

  Moreover, when the peeling layer 5 or the adhesive layer 6 and the decorative pattern layer 3 and the hard coat layer 4 have poor adhesion, an anchor layer may be provided as necessary.

  The material of the anchor layer is acrylic resin, vinyl chloride resin, polyurethane resin, polyester resin, polypropylene resin, polyethylene resin, polystyrene resin, polycarbonate resin, vinylon resin, acetate resin, polyamide resin A preferable material is appropriately selected according to the adhesion to each layer.

  The thickness of the anchor layer is preferably 0.5 μm to 50 μm. If the film thickness is less than 0.5 μm, there is a problem that sufficient adhesion cannot be obtained, and if it is more than 50 μm, there is a problem that it is difficult to dry after printing.

  The formation method of the anchor layer may be a method such as gravure printing, offset printing, or screen printing, or a method such as painting, dipping, or reverse coater.

  An injection mold was prepared in which a hemispherical recess having a depth of 0.1 mm and a diameter of 0.2 mm was formed on the entire surface of the mold A.

  Next, using a 38 μm polyethylene terephthalate film as a base sheet, printing an ink comprising a urethane acrylate ultraviolet / thermosetting resin, heating it at 80 ° C. for 30 seconds and drying it by touching it, a 2 μm semi-cured hard After forming the coat layer, a hard coat sheet was prepared on which an adhesive layer made of a vinyl chloride resin was sequentially printed. This hard coat sheet was set on the A mold side of the injection mold.

  On the other hand, a 38 μm polyethylene terephthalate film is used as a base sheet, a 1 μm release layer made of an acrylic resin, a 2 μm decorative pattern layer made of urethane resin and made of N letters on the top, bottom, left and right surfaces, and then a vinyl chloride resin. A decorative sheet on which adhesive layers were sequentially printed and formed was prepared. This decorative sheet was set on the B mold side of the injection mold.

  Next, after filling the molding space formed between the hard coat sheet and the decorative sheet with a transparent polycarbonate molding resin and integrating with both sheets, the base sheet of both sheets was peeled and removed, A convex lens portion is formed on the entire surface of the molded resin layer, a semi-cured hard coat layer is formed on the convex lens portion, and a molded simultaneous decorative molded product with a convex lens having an excellent design property in which the letter N exhibits a lens effect is obtained. It was.

  Then, when the semi-cured hard coat layer of this injection molded decorative molded product with a convex lens was irradiated with an ultraviolet ray of 300 mJ, a simultaneous decorative molded product with a convex lens having excellent wear resistance and scratch resistance was obtained. .

  An injection mold was prepared in which a substantially hemispherical recess having a depth of 0.15 mm and a diameter of 0.35 mm was formed on a part of the surface of the A mold.

  Next, after a 125 μm polycarbonate film is used as a base sheet, an ink made of a thermosetting acrylic resin is printed, heated at 60 ° C. for 30 seconds, and dried by touching to form a 1 μm semi-cured hard coat layer A hard coat sheet in which an adhesive layer made of a vinyl chloride resin was sequentially formed thereon was prepared. This hard coat sheet was set on the A mold side of the injection mold.

  On the other hand, a decorative sheet in which a 125 μm polycarbonate film was used as a base sheet, a 2 μm decorative pattern layer made of acrylic resin and made of letter N, and then an adhesive layer made of vinyl chloride resin was prepared. This decorative sheet was set on the B mold side of the injection mold.

  When the molding space formed between both sheets is filled with a transparent polycarbonate molding resin and integrated with the decorative sheet, a convex lens portion is formed on a part of the surface of the molding resin layer, and on the convex lens portion. A semi-cured hard coat layer was formed, and a molded simultaneous decorative molded product with a convex lens excellent in design, in which the letter N exhibited a lens effect, was obtained.

  Then, when this molded simultaneous decorative molded product with a convex lens was heated at 150 ° C. for 1 hour, a molded simultaneous decorative molded product with a convex lens excellent in abrasion resistance and scratch resistance was obtained.

  In the present invention, one surface of a transparent injection-molded resin layer is composed of a plurality of hemispherical convex lens portions, and a transparent hard coat layer is formed on the surface of the convex lens portion of the injection-molded resin layer. The present invention relates to a molded simultaneous decorative molded product with a convex lens in which a decorative pattern layer is provided on the surface opposite to the surface, and a method for producing the same.

It is sectional drawing which shows one Example of the shaping | molding simultaneous decorating molded product with a convex lens which concerns on this invention. It is sectional drawing which shows one Example of the injection-molding die used for the manufacturing method of the shaping | molding simultaneous decorating molded product with a convex lens concerning this invention. It is sectional drawing which shows one Example of the decorating sheet used for the manufacturing method of the shaping | molding simultaneous decorating molded product with a convex lens concerning this invention. It is sectional drawing which shows one Example of the decorating sheet used for the manufacturing method of the shaping | molding simultaneous decorating molded product with a convex lens concerning this invention. It is sectional drawing which shows one Example of the hard-coat sheet used for the manufacturing method of the shaping | molding simultaneous decorating molded product with a convex lens concerning this invention. It is sectional drawing which shows one Example of the hard-coat sheet used for the manufacturing method of the shaping | molding simultaneous decorating molded product with a convex lens concerning this invention.

Explanation of symbols

1 Base sheet
2 Convex lens
3 decoration pattern layers
4 Hard coat layer
5 Release layer
6 Adhesive layer
8 Molding space
DESCRIPTION OF SYMBOLS 9 Molding resin 10 Decoration sheet 11 Hard coat sheet 15 Injection molding resin layer 20 A metal mold | die 21 B metal mold | die 22 Recessed part 30 Molding simultaneous decorative molded product with a convex lens

Claims (2)

One surface of the transparent injection-molded resin layer is composed of a plurality of substantially hemispherical convex lens portions, a transparent hard coat layer is formed on the surface of the convex lens portion of the injection-molded resin layer, and a hard coat layer forming surface of the molded resin layer Molded simultaneous decorative molded product with a convex lens with a decorative pattern layer on the opposite surface. An injection mold B mold is formed by arranging a decorative sheet having an uncured or semi-cured transparent hard coat layer on an A mold of an injection mold having a plurality of substantially hemispherical recesses. A decorative sheet provided with a decorative pattern layer is placed on the mold, and a molding space is formed by closing the molds of the A mold and the B mold, and then a molding resin is injected into the molding space to inject an injection molded product. Forming an uncured or semi-cured transparent hard coat layer and a decorative pattern layer on the surface of the injection-molded article and simultaneously curing the uncured or semi-cured hard coat layer. Item 2. A method for producing a molded simultaneous decorative molded product with a convex lens according to Item 1.

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