JP2006015634A - Metallic tone decorative sheet and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a metallic tone decorative sheet which can be used for the manufacture of a metallic tone resin molded object having homogeneity and successful metallic luster which are equal to a conventional molded object manufactured by plating or coating and easily recycled, and a method for manufacturing this metallic tone decorative sheet. <P>SOLUTION: This metallic tone decorative sheet 10 has a base material sheet 11 composed of a thermoplastic resin, a metallic design sheet 13 laminated on the base material sheet 11 through a first adhesive layer 12 and an acrylic resin sheet 15 laminated on the metallic design sheet 13 through a second adhesive layer 14. The metallic design sheet 13 is formed of a PET sheet 13a and a metallic vapor deposition layer or a metallic spatter layer 13b formed on one surface of the PET sheet 13a and, besides, in such a way that the metallic vapor deposition layer or the metallic spatter layer 13b is arranged adjacent to the second adhesive layer 14. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a metallic decorative sheet used when a resin molded product having a metallic surface is produced by insert molding or the like, and a method for producing the metallic decorative sheet.

Conventionally, a resin molded product with a metallic surface such as a center emblem of a wheel cap is formed by first molding a resin as described in the prior art of Patent Document 1, and then on the surface of the obtained resin molded product. It has been manufactured by methods such as plating and painting.
However, there is a problem that waste water generated in the plating process and organic solvents used for coating are environmentally undesirable. Moreover, since the metal foil formed by plating is relatively thick, it has been difficult to recycle a resin molded product including such a metal foil as a resin.
Therefore, recently, a decorative sheet with a metal layer thinner than the metal foil is pre-formed by vacuum forming as a method of manufacturing a resin molded product with the same metallic luster without plating or painting. Then, insert molding in which the molded decorative sheet is placed in a mold and then molten resin is injected and integrated has been studied.
Japanese Patent No. 2981475

  However, in such a method, when vacuum forming or insert molding is performed, the appearance of the metal layer becomes inhomogeneous or cracks occur in the metal layer, so that the resin molding with the same metallic luster as before is performed. It was difficult to manufacture the product.

  The present invention has been made in view of the above circumstances, and even when a deep-drawn metal-like resin molded product is manufactured by vacuum forming or insert molding, cracks do not occur, and the conventional manufacturing is performed by plating or painting. It is an object of the present invention to provide a metal-like decorative sheet that can produce a metal-like resin molded product that exhibits a uniform and good metallic luster equivalent to a product and is easy to recycle.

The metallic decorative sheet of the present invention comprises a base sheet made of a thermoplastic resin, a metal design sheet laminated on the base sheet via a first adhesive layer, and a second adhesive layer on the metal design sheet. And the metal design sheet comprises a PET sheet and a metal vapor deposition layer or a metal sputter layer formed on one side of the PET sheet, the metal vapor deposition layer or the metal sputter layer and the above It arrange | positions so that a 2nd contact bonding layer may contact | connect.
The method for producing a metal-like decorative sheet according to the present invention includes the base sheet and the metal design sheet stacked via the first adhesive layer such that the metal vapor-deposited layer or the metal sputter layer is on the outside. The acrylic resin sheet is laminated on the metal design sheet with the second adhesive layer interposed therebetween between the first pressing surface of the thermocompression bonding means provided with a pair of mirror-finished pressing surfaces. And a second step.
The thermocompression bonding means is wound around a pair of heating rolls, a pair of cooling rolls provided on the rear side of the heating rolls, and the same side of the heating rolls and the cooling rolls, and the opposing surfaces are the pressing surfaces It is preferable to include a pair of endless metal belts that are surfaces, and a pair of pressurizing means that act so that the pressing surfaces of the endless metal belt come close to each other.
The metallic decorative sheet of the present invention is suitable for use in an insert molded product.

  According to the present invention, even when a deep-drawn metallic resin molded product is manufactured by vacuum forming or insert molding, cracks do not occur, and it is as homogeneous and good as conventional products manufactured by plating or painting. It is possible to provide a metal-like decorative sheet that can produce a metallic resin-molded product that exhibits an excellent metallic luster and is easy to recycle.

Hereinafter, the present invention will be described in detail with reference to the drawings.
FIG. 1 is an example of a metallic decorative sheet (hereinafter referred to as a decorative sheet) 10 according to the present invention, and a first adhesive layer 12 is formed on a base sheet 11 made of ABS resin having a thickness of 0.36 mm. And the acrylic resin sheet 15 having a thickness of 0.075 mm laminated on the metal design sheet 13 via the second adhesive layer 14.

The material of the base sheet 11 is not limited to ABS, and thermoplastic resins other than ABS such as polyvinyl chloride (PVC), polypropylene (PP), and polyethylene (PE) can also be used. A laminated sheet of a plurality of resins may be used. For example, thermoplastic urethane resin (TPU) has excellent adhesion to polyamide. Therefore, when arranging a decorative sheet by insert molding on the surface of a polyamide molded product, a decorative sheet comprising a laminated sheet of TPU and ABS is used as the base sheet 11 so that the molten polyamide resin is in contact with the TPU side. By injecting this, an insert molded product in which the decorative sheet and the polyamide are more firmly integrated can be manufactured.
Moreover, although the thickness of the base material sheet 11 can be suitably set according to the material, the use of the decorative sheet 10, etc., it is the range of 0.2-1.0 mm normally.

  The metal design sheet 13 in this example includes a moldable PET sheet 13a having a thickness of 0.016 mm, and a stainless steel metal deposition layer or a metal sputter layer 13b formed on one surface of the PET sheet 13a. The layer or metal sputter layer 13b and the second adhesive layer 14 are disposed in contact with each other. Here, the PET sheet 13a has excellent adhesion to the metal vapor deposition layer or the metal sputter layer 13b, and can form a uniform, smooth and dense metal vapor deposition layer or the metal sputter layer 13b on the surface thereof as described in detail later. Therefore, it is preferably used.

The formable PET sheet 13a has a high elongation while maintaining the original strength of the PET sheet, and is excellent in moldability. As a specific example, Teflex FT3 manufactured by Teijin DuPont Films Ltd. And QT10 manufactured by Toray Industries, Inc.
The preferable physical properties of the moldable PET sheet 13a are as follows: tensile strength according to JIS K7161 is 150 to 230 MPa, elongation is 140 to 190%, and heat shrinkage is 1.0 to 5.0%. The PET sheet 13a has a tensile strength of 177 MPa, an elongation rate of 160%, and a heat shrinkage rate of 5%. When the physical properties of the PET sheet 13a are within the above range, the follow-up property of the decorative sheet 10 when vacuum-molded or further used for insert molding is excellent, and even a deep-drawn molded product is good. Can be manufactured. Although there is no restriction | limiting in the thickness of the moldable PET sheet 13a, 10-50 micrometers is preferable from the point of a moldability and intensity | strength.

The metal vapor deposition layer or metal sputter layer (hereinafter referred to as metal layer) 13b is formed on the PET sheet 13a by a vacuum vapor deposition method or a sputtering method. According to the vacuum deposition method or the sputtering method, the metal layer 13b having a metallic luster can be formed with a small amount of metal. Therefore, the resin molded product in which the decorative sheet 10 having the metal layer 13b is used is recycled as a resin. It is also possible. Examples of the metal species include stainless steel, aluminum, indium, chromium, zinc, gallium, nickel, tin, silver, gold, silicon, titanium, platinum, palladium, hastelloy, and the like. Among these, stainless steel is preferable because the metal layer 13b having excellent adhesion can be formed.
The thickness of the metal layer 13b is 10-100 nm normally, Preferably it is 20-40 nm. Within this range, a sufficient metallic luster can be imparted more economically.

  The acrylic resin sheet 15 is disposed on the outside of the metal design sheet 13 to protect the metal layer 13b and to impart properties such as hardness and weather resistance to the decorative sheet 10. Although there is no restriction | limiting in particular as the thickness of the acrylic resin sheet 15, Usually, it is 0.050-0.125 mm from being able to fully provide these characteristics.

The first adhesive layer 12 for adhering the base sheet 11 and the metal design sheet 13 and the second adhesive layer 14 for adhering the metal design sheet 13 and the acrylic resin sheet 15 are adhesives capable of adhering them. Specific examples of adhesives include polyurethane, polyester, polyethylene, polyamide, polyvinyl chloride, polychloroprene, carboxylated rubber, thermoplastic styrene-butadiene rubber, acrylic Styrene, cellulose, alkyd, polyvinyl acetate, ethylene vinyl acetate copolymer, polyvinyl alcohol, epoxy, silicone, natural rubber, and synthetic rubber.
Moreover, although there is no restriction | limiting in the thickness of the 1st contact bonding layer 12 and the 2nd contact bonding layer 14, Usually, it is 1.0-20 micrometers. In this example, the first adhesive layer 12 is formed from a polyester adhesive having a thickness of 3 μm, and the second adhesive layer 14 is formed from an acrylic adhesive having a thickness of 15 μm.

Next, the suitable manufacturing method of the decorative sheet 10 of this example is demonstrated.
First, the base material sheet 11 and the metal design sheet 13 are overlapped via the first adhesive layer 12 so that the metal layer 13b is on the outside, and supplied to the thermocompression bonding means 30 in FIG. In this example, the first adhesive layer 12 is formed in advance on the surface of the PET sheet 13 a in the metal design sheet 13.

  The thermocompression bonding means 30 of this example is provided with a pair of heating rolls 31 in which a heating medium oil (not shown) is internally circulated and heated to a predetermined temperature, and on the rear stage side of the heating roll 31, and is below a predetermined temperature. A pair of controlled cooling rolls 32 and a pair of endless metal belts 33 wound around the same side of the heating roll 31 and the cooling roll 32 are provided.

  Here, the opposed surfaces of the endless metal belt 33 are arranged with a predetermined distance from each other, and are respectively made of stainless steel pressing surfaces 33a and 33b having a mirror finish. Further, the thermocompression bonding means 30 is further provided with a pair of pressurizing means 34 that act so that the pressing surfaces 33a and 33b approach each other by press-fitting a fluid pressure medium such as hydrocarbon synthetic oil, The pressure when the pressing surfaces 33a and 33b are brought closer to each other can be controlled by changing the supply amount of the fluid pressure medium to be pressed, and the surface temperature of the pressing surfaces 33a and 33b can be controlled by changing the temperature of the fluid pressure medium. It has become. The pair of pressurizing means 34 in this example is divided into a front stage side 34a and a rear stage side 34b, and the supply amount and temperature of the fluid pressure medium can be independently controlled for each.

  When the base material sheet 11 and the metal design sheet 13 stacked via the first adhesive layer 12 are supplied between the pressing surfaces 33a and 33b facing each other, the base material sheet 11 and the metal design sheet are provided. First, the sheet 13 is uniformly heated to about 150 ° C. by the endless metal belt 33 heated by the heating roll 31.

Next, the fluid pressure medium whose temperature is controlled to 150 ° C. is press-fitted into the front stage side 34 a and the rear stage side 34 b of the pressurizing means 34, and the pressing surfaces 33 a and 33 b approach each other so that the base sheet 11 and the metal design sheet 13 are moved. It clamps and it cools while pressing with the pressure of about 20-30 MPa.
As a result, the base material sheet 11 and the metal design sheet are thermocompression bonded via the first adhesive layer 12, and the metal layer 13b of the metal design sheet 13 is applied to the upper mirror-finished pressing surface 33a in the drawing. While being pressed directly, it is heated and cooled to homogenize, smooth and densify.

  Next, the base sheet 11 and the metal design sheet 13 laminated via the first adhesive layer 12 are sent to the pair of cooling rolls 32 while being sandwiched between the pressing surfaces 33a and 33b. It is cooled uniformly to 60 ° C. or less by the action of 32.

In this way, in the first step, the base sheet 11 and the metal design sheet 13 are sandwiched between the pressing surfaces 33a and 33b and thermocompression bonded, and the metal layer 13b in the metal design sheet 13 is homogenized, smoothed and smoothed. After performing the densification process, a second step of laminating the acrylic resin sheet 15 via the second adhesive layer 14 is performed on the metal layer 13b.
Although there is no restriction | limiting in particular in the specific method of a 2nd process, the acrylic resin sheet 15 in which the 2nd contact bonding layer 14 was formed in advance on one side is arranged on the metal layer 13b of the metal design sheet 13, and these, For example, a method of thermocompression bonding with a normal thermocompression bonding means provided with a pair of thermocompression-bonding rolls, or a method of thermocompression bonding using the thermocompression bonding means 30 shown in FIG. The heating temperature at the time of thermocompression bonding is about 80 to 150 ° C.

In such a manufacturing method of the decorative sheet 10, first, in the first step, the acrylic resin sheet 15 is not overlapped, and only the base sheet 11 and the metal design sheet 13 are overlapped via the first adhesive layer 12 and thermocompression bonded. Since it is supplied to the means 30, not only the base sheet 11 and the metal design sheet 13 are thermocompression bonded, but also the metal layer 13b in the metal design sheet 13 is directly pressed against the pressing surface 33a having a mirror finish, As a result, the metal layer 13b is homogenized, smoothed and densified. By homogenizing and densifying in this way, the metal layer 13b is improved in resistance to heating and pressurization received during subsequent vacuum forming and insert molding, cracks are not generated, and by smoothing, A better metallic luster is developed. Further, since the PET sheet 13a is particularly disposed below the metal layer 13b, the metal layer 13b is sufficiently homogenized, smoothed and densified by such pressing.
Therefore, the decorative sheet 10 obtained by further laminating the acrylic resin sheet 15 in the second step is subjected to vacuum forming or insert molding, and even when a deep-drawn molded product is manufactured, cracks do not occur and are uniform. It can exhibit good metallic luster.

The decorative sheet 10 obtained in this way is used for electrical appliances such as the handle and surface material of a refrigerator, the surface of a key part of a personal computer, a mobile phone, etc. It can be suitably used for manufacturing various insert-molded products such as building material applications such as postbox frames and design material applications such as bag molding materials.
Insert molding may be performed by a normal method in which the decorative sheet 10 is placed in a mold and then molten resin is injected into the mold.

The thermocompression bonding means 30 is not limited to the example of FIG. 2, and various press devices can be used as long as they have a pair of mirror-finished pressing surfaces. However, it can be uniformly heated by the endless metal belt 33 heated by the heating roll 31, and can be pressed and cooled with a uniform pressure by the action of the pressurizing means 34, so that a more uniform, smooth and dense metal layer 13b can be formed. Therefore, it is preferable to use an apparatus like the example of FIG. The pressurizing means 34 may not be a type using a fluid pressure medium as in this example, or may be a type divided into two parts, the front stage side 34a and the rear stage side 34b.
Further, the first adhesive layer 12 and the second adhesive layer 14 may not be formed in advance on the surfaces of the PET sheet 13a and the acrylic resin sheet 15, respectively. For example, application means such as a roll coater in the middle of the process Then, it may be formed by applying to the surface of the PET sheet 13a or the base sheet 11, the surface of the acrylic resin sheet 15 or the metal layer 13b.

It is sectional drawing which shows an example of the metallic tone decorative sheet of this invention. It is a schematic block diagram which shows the thermocompression-bonding means used with the manufacturing method of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Metal-like decorative sheet 11 Base material sheet 12 1st adhesion layer 13 Metal design sheet 13a PET sheet 13b Metal vapor deposition layer or metal sputter layer 14 2nd adhesion layer 15 Acrylic resin sheet 30 Thermocompression-bonding means 31 Heating roll 32 Cooling roll 33 Endless metal belt 33a, 33b Pressing surface 34 Pressurizing means

Claims (4)

A base material sheet made of a thermoplastic resin, a metal design sheet laminated on the base material sheet via a first adhesive layer, and an acrylic resin sheet laminated on the metal design sheet via a second adhesive layer Prepared,
The metal design sheet includes a PET sheet and a metal vapor deposition layer or a metal sputter layer formed on one side of the PET sheet, and is disposed so that the metal vapor deposition layer or the metal sputter layer and the second adhesive layer are in contact with each other. Metallic decorative sheet characterized by being made. It is a manufacturing method of the metal-like decorative sheet according to claim 1,
Provided with a pair of mirror-finished pressing surfaces, the base sheet and the metal design sheet stacked via the first adhesive layer so that the metal deposition layer or the metal sputter layer is on the outside A first step of clamping between the pressing surfaces of the thermocompression bonding means;
And a second step of laminating the acrylic resin sheet on the metal design sheet via the second adhesive layer. The thermocompression bonding means is
A pair of heating rolls;
A pair of cooling rolls provided on the rear side of the heating roll;
A pair of endless metal belts that are respectively hung on the same side of the heating roll and the cooling roll and whose opposing surfaces are the pressing surfaces;
The method for producing a metallic decorative sheet according to claim 2, further comprising a pair of pressing means that act so that the pressing surfaces of the endless metal belt approach each other. An insert-molded product comprising the metallic decorative sheet according to claim 1.

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