JP2006240156A - Brilliant decorative sheet and method of manufacturing brilliant decorative molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a brilliant decorative sheet having no occurrence fear of a crack in a brilliant layer even in a case that the brilliant decorative sheet is inserted after preformed, and a method of manufacturing a brilliant decorative molded product. <P>SOLUTION: The brilliant decorative sheet is constituted by forming at least the brilliant layer, which comprises ink containing a brilliant pigment, on a thermoformable substrate sheet and, since the brilliant layer contains 30-50 wt% of a vinyl chloride/vinyl acetate copolymer resin, the brilliancy of the brilliant decorative sheet is not damaged by processing which accompanies stretching. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a glittering decorative sheet and a method for producing a glittering decorative molded product in which no crack is generated in the glittering layer even when the glittering decorative sheet is inserted after being preformed.

Conventionally, as a method of decorating a plastic molded article or the like, a glittering decorative sheet in which a glittering layer made of ink containing a glittering pigment is formed on a base sheet is used in an injection mold. There is a method of performing decoration by adhering a glittering decorative sheet integrally to a molded product at the same time as forming a three-dimensional molded product. Since the glittering decorative sheet having such a configuration has a glittering layer, it is possible to express a pattern having high glitteriness utilizing metallic luster (for example, see Patent Document 1).
JP 2001-310414 A

  As a base sheet for a glittering decorative sheet, a film made of acrylic resin, polycarbonate resin, vinyl chloride resin, polyester resin, non-crystalline or low-crystalline polypropylene resin, etc., because three-dimensional processability is required. Is used. In addition, fine powder made of aluminum or the like is used as the bright pigment.

  The glittering decorative sheet used to decorate three-dimensional molded products is preliminarily molded into a desired cavity shape by a method such as die pressing, vacuum molding, and pressure forming, and then the glittering decorative sheet is preformed. After the sheet is placed in the mold and clamped, the molten ABS resin is injected, cooled and solidified, and the mold is opened to obtain a glittering decorative molded product.

  The glittering decorative sheet after the preforming is preferably the same shape as the cavity shape of the mold to be inserted, but actually the thickness of the glittering decorative sheet is partially increased by stretching during the preforming. Due to the difference, it is difficult to perfectly match the shape of the glittering decorative sheet with the cavity shape.

  In addition, if the glittering decorative sheet after preforming is larger than the mold shape, it cannot be inserted into the mold, and even if it can be inserted, there is a problem of appearance such as wrinkles due to sagging. Arise.

  Accordingly, the pre-formed glittering decorative sheet has a shape that is at least partially smaller than the cavity shape of the mold.

  However, when the pre-molded glittering decorative sheet is at least partially smaller than the cavity shape of the mold, the glittering decorative sheet is softened by heating as in pre-molding during injection molding. Although it is partially and very small due to the molding resin pressure without passing through the film, since it is stretched rapidly, a partial crack (break) may occur in the glitter layer. In particular, when the glitter layer contains an aluminum pigment, even if it is a fine crack, it becomes easy to be visible, which may cause a problem in appearance.

  Therefore, the present invention eliminates the above-described drawbacks, and even when the glittering decorative sheet is inserted after being preformed, the glittering decorative sheet and the glittering decorating are not generated in the glittering layer. It aims at providing the manufacturing method of a decorative molded product.

  The production method of the glittering decorative sheet and the glittering decorative molded product of the present invention is configured as follows in order to achieve the above object.

  That is, in the glittering decorative sheet of the first aspect of the present invention, at least a glittering layer made of ink containing a glittering pigment is formed on a thermoformable base sheet, and the glittering layer is 30 to 50% by weight. By including a vinyl chloride-vinyl acetate copolymer resin, the glitter was not impaired even by processing with stretching.

  Further, as the second aspect of the invention, the glittering decorative sheet of the first aspect is configured such that the base sheet is composed of any one of acrylonitrile-butadiene-styrene resin, polypropylene resin, and polystyrene resin. You can also

  In addition, as the third aspect of the invention, the glittering decorative sheet according to the first and second aspects can be configured such that the glitter layer contains an aluminum flake pigment.

  Moreover, the manufacturing method of the glittering decorative molded product according to the fourth aspect of the present invention is that the glittering decorative sheet according to any one of claims 1 to 3 is softened by heating in advance, and then vacuum or compressed air is used. Perform pre-molding, then place it in an injection mold and clamp it, then inject the molding resin into the cavity to integrate the glitter decorative sheet and the resin molded product so that the stretched area has glitter It constituted so that the decorative molded product which may not be impaired was obtained.

  In the glittering decorative sheet of the present invention, at least a glittering layer made of ink containing a glittering pigment is formed on a thermoformable base sheet, and the vinyl chloride vinyl acetate copolymer having a glittering layer of 30 to 50% by weight is formed. By including a systemic resin, it is configured so that the glitter is not impaired even by processing with stretching, so even if the glitter decorative sheet is pre-molded and inserted, cracks in the glitter layer It may not occur.

  The method for producing a glittering decorative molded product according to the present invention comprises preliminarily molding the glittering decorative sheet according to any one of claims 1 to 3 in advance by softening by heating, then vacuum or compressed air, Decorative molding in which the glittering decorative sheet and the resin molded product are integrated and the glittering properties of the stretched part are not impaired by injecting molding resin into the cavity after being placed in the injection mold and clamped Since it was comprised so that a product might be obtained, even if it inserts after pre-molding a glittering decorative sheet, a glittering decorative molded product can be obtained without generating a crack in a glittering layer.

  Embodiments of the present invention will be described in detail with reference to the drawings.

  1-3 is sectional drawing which shows one Example of the glittering decorating sheet | seat of this invention. FIG. 4 is a cross-sectional view showing an embodiment of a transfer sheet used for producing the glittering decorative sheet of the present invention. 5-6 is sectional drawing which shows 1 process of the manufacturing method of the glittering decorative molded product of this invention. FIG. 7 is a cross-sectional view showing an example of a glittering decorative molded product obtained by the method for producing a glittering decorative molded product of the present invention.

  In the figure, 1 is a glittering decorative sheet, 2 is a base sheet, 3 is a glittering layer, 4 is a surface protective layer, 5 is a design layer, 6 is a glittering layer adhesive layer, 7 is a decorative sheet adhesive layer, and 8 is a transfer. A sheet, 9 is a transfer substrate, 10 is a release layer, 11 is a release layer, 12 is a preforming mold, 13 is an injection mold, 14 is a resin molded product, and 15 is a glittering decorative molded product. In addition, the same code | symbol is attached | subjected about the same component in each figure.

  In the glittering decorative sheet 1 according to the embodiment of the present invention, at least a glittering layer 3 made of ink containing a glittering pigment is formed on a thermoformable base sheet 2, and the glittering layer 3 is 30 to 50 weights. % Of vinyl chloride / vinyl acetate copolymer-based resin is configured such that the glitter is not impaired even by processing with stretching (see FIGS. 1 to 3).

  The base sheet 2 prevents other layers from being damaged by the impact of the injected molten resin, and maintains the shape when the decorative sheet is deformed into a three-dimensional shape by vacuum forming or pressure forming. For the base sheet 2, acrylonitrile-butadiene-styrene resin, polypropylene resin, or polystyrene resin may be used. In particular, acrylonitrile-butadiene-styrene resin is not only acrylonitrile-butadiene-styrene resin as molding resin, but also acrylic resin, polycarbonate resin, alloy resin of polycarbonate resin and acrylonitrile-butadiene-styrene resin, etc. In addition, it is preferable because it can be bonded. The film thickness of the base sheet 2 is generally 100 to 1000 μm. In particular, 200 to 500 μm is preferable. If it is less than 100 μm, it is difficult to maintain the shape after being transformed into a three-dimensional shape.

  As the material of the bright layer 3, an acrylic resin, a urethane resin, a two-component curable urethane resin using an aromatic isocyanate, or the like as a resin binder and an aluminum metal pigment can be used.

  In the present invention, it is important that the glitter layer 3 contains 30 to 50% by weight of vinyl chloride / vinyl acetate copolymer resin. When the glitter layer 3 contains 30 to 50% by weight of vinyl chloride / vinyl acetate copolymer resin with respect to the entire binder, the glitter is not impaired even by processing with stretching. If the vinyl chloride vinyl acetate copolymer resin is less than 30% by weight, fine cracks are generated when the glitter layer 3 is stretched, and the orientation of the glitter pigment exhibiting glitter is disturbed, resulting in a loss of glitter. The problem that occurs. On the other hand, if the vinyl chloride / vinyl acetate copolymer resin exceeds 50% by weight, the brightness of the glitter layer 3 is impaired.

  The bright pigment is a pigment having high brightness such as an aluminum flake pigment or a pearl pigment, for example, a pigment having a flake shape of 1 to 20 μm and uniformly dispersed and arranged in the ink film.

  As a method for forming the glitter layer 3, a normal printing method such as an offset printing method, a gravure printing method, a screen printing method, or the like can be used.

  A surface protective layer 4 may be formed on the glitter as required (see FIG. 2). The surface protective layer 4 aims to improve the corrosion resistance, crack resistance, weather resistance, and scratch resistance of the glitter layer 3. Examples of the material for forming the surface protective layer 4 by a printing method or a coating method include acrylic resins and acrylic urethane resins. An electron beam curable material or an ultraviolet curable material containing a photopolymerization initiator in these resins may be used. Examples of the printing method include a known printing method such as a gravure printing method. Examples of the coating method include known coating methods such as a gravure coating method, a silk coating method, a lip coating method, and a reverse coating method. Examples of the material for forming the surface protective layer 4 as a thermoformable sheet include acrylic resins, polycarbonate resins, and fluorine-containing acrylic resins. A sheet obtained by laminating a sheet made of polycarbonate resin and a sheet made of polybutylene terephthalate resin may be used as the surface protective layer 4.

  Moreover, you may form the symbol layer 5 in order to express a various symbol as needed (refer FIG. 3). The design layer 5 is a layer that expresses decoration in addition to the metallic luster of the glitter layer 3, and more specifically, designs such as letters and symbols, solid designs, wood designs, stone designs, carbon cloth Examples include patterns such as patterns. The pattern layer 5 may be partially provided. As a material of the pattern layer 5, a binder such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, or an alkyd resin is used as a binder. And a color ink containing an appropriate color pigment or dye as a colorant may be used. The pattern layer 5 may be formed by a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method, or a coating method such as a roll coating method or a spray coating method. The thickness of the pattern layer 5 is preferably 0.1 to 20 μm. According to the normal printing method, it is in this range.

  Moreover, you may form the glitter layer contact bonding layer 6 between the base sheet 2 and the glitter layer 3 as needed (refer FIG. 3). The glitter layer adhesive layer 6 is intended to improve the adhesion strength with the glitter layer 3. As the material of the glitter layer adhesive layer 6, it is preferable to use vinyl chloride vinyl acetate copolymer resin or the like. Further, in accordance with the material of the base sheet 2, a resin having affinity with these resins may be used as the material for the glitter layer adhesive layer 6. As a method for forming the glitter layer adhesive layer 6, there is a known printing method such as a gravure printing method. Further, it may be formed by a known coating method such as a gravure coating method, a silk coating method, a lip coating method, or a reverse coating method. The film thickness of the glitter layer adhesive layer 6 is generally 1.0 to 6.0 μm. When the glittering decorative sheet 1 has a large stretch ratio during preforming, it is better to set the film thickness to be large.

  Moreover, you may form the decorating sheet contact bonding layer 7 in order to adhere | attach the glittering decorating sheet 1 and the resin molded product 14 as needed (refer FIG. 3). The decorative sheet adhesive layer 7 adheres each of the above layers to the surface of the transfer object. As the decorative sheet adhesive layer 7, a heat-sensitive or pressure-sensitive resin suitable for the material of the resin molded product 14 is appropriately used. For example, when the material of the resin molded product 14 is an acrylic resin, an acrylic resin may be used. Further, when the material of the resin molded product 14 is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, A polyamide resin or the like may be used. Furthermore, when the material of the resin molded product 14 is a polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used. Examples of the method for forming the decorative sheet adhesive layer 7 include a coating method such as a gravure coating method, a roll coating method and a comma coating method, a printing method such as a gravure printing method and a screen printing method.

  As a method for forming the above-mentioned glitter layer 3, surface protective layer 4, design layer 5, glitter layer adhesive layer 6 and the like on the thermoformable base sheet 2, the glitter layer 3 is formed on the thermoformable base sheet 2. There is a method of directly printing the surface protective layer 4 sequentially.

  Further, when the dimensional stability of the base sheet 2 is low, a transfer sheet 8 in which a glitter layer 3, a surface protective layer 4, a pattern layer 5, a glitter layer adhesive layer 6 and the like are formed on a transfer substrate 9 is used. There is a method of transferring each layer on the transfer sheet 8 onto the base sheet 2 that can be thermoformed.

  The structure of the transfer sheet 8 is such that the glitter layer 3 and the like are formed on a transfer substrate 9 excellent in dimensional stability (see FIG. 4).

  Materials for the transfer substrate 9 include polypropylene resin, polyethylene resin, polyamide resin, polyester resin, acrylic resin, polyvinyl chloride resin resin sheet, aluminum foil, copper foil and other metal foil, glassine A sheet having excellent dimensional stability used as a transfer substrate 9 of a normal transfer sheet 8, such as a cellulose-based sheet such as paper, coated paper, and cellophane, or a composite of each of the above-described sheets can be used.

  When the peelability of the transfer layer from the transfer substrate 9 is good, the transfer layer may be provided directly on the transfer substrate 9. In order to improve the peelability of the transfer layer from the transfer substrate 9, the release layer 10 may be formed on the entire surface before providing the transfer layer on the transfer substrate 9. The release layer 10 is released from the transfer layer together with the transfer substrate 9 when the transfer substrate 9 is peeled off after the transfer. As a material of the release layer 10, melamine resin release agent, silicone resin release agent, fluororesin release agent, cellulose derivative release agent, urea resin release agent, polyolefin resin release agent Paraffin type release agents and composite release agents thereof can be used. Examples of the method for forming the release layer 10 include a coating method such as a roll coating method and a spray coating method, a printing method such as a gravure printing method, and a screen printing method.

  The release layer 11 is formed on the transfer substrate 9 or the release layer 10. When the transfer base material 9 is peeled off after transfer, the release layer 11 is peeled off from the transfer base material 9 or the release layer 10 and positioned on the outermost surface. Examples of the material of the release layer 11 include acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, and vinyl chloride-vinyl acetate copolymer. Copolymers such as system resins and ethylene-vinyl acetate copolymer resins may be used. When the release layer 11 requires hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used. If the release layer 11 has a high hardness, it functions as the surface protective layer 4 after transfer. The release layer 11 may be colored or uncolored. Examples of the method for forming the release layer 11 include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

  The glitter layer 3 formed as the transfer layer may be formed in the same manner as described above. The pattern layer 5 and the glitter layer adhesive layer 6 formed as the transfer layer may be formed in the same manner as described above.

  A method for forming the glitter layer 3 on the surface of the base sheet 2 using the transfer sheet 8 having such a layer structure will be described. First, the adhesive layer side of the transfer sheet 8 is brought into close contact with the surface of the base sheet 2. Next, using a transfer machine such as a roll transfer machine or an up-down transfer machine equipped with a heat-resistant rubber-like elastic body such as silicon rubber, a heat-resistant rubber-like condition set at a temperature of about 80 to 260 ° C. and a pressure of about 490 to 1960 Pa. Heat and pressure are applied from the transfer substrate 9 side of the transfer sheet 8 via an elastic body. By doing so, the adhesive layer adheres to the surface of the base sheet 2. Finally, when the transfer base material 9 is peeled off after cooling, peeling occurs at the interface between the transfer base material 9 and the release layer 11, and the transfer is completed. Further, when the release layer 10 is provided on the transfer substrate 9, when the transfer substrate 9 is peeled off, peeling occurs at the boundary surface between the release layer 10 and the release layer 11, and the transfer is completed.

  Next, the preforming of the glittering decorative sheet 1 of the present invention will be described (see FIG. 5). Prior to the main molding, the glittering decorative sheet 1 is three-dimensionally molded in advance so as to conform to the desired cavity shape, so that no excessive stress is applied to the glittering decorative sheet 1 during the main molding, so that the glittering property is achieved. The decorative sheet 1 can be beautifully decorated without wrinkles or the like.

  For the preliminary molding, it is preferable to use a die press, vacuum molding, pressure molding or the like according to the size and shape of the molded product. Moreover, in order to heat the glittering decoration sheet 1 and to make it easy to follow the preforming die 12, the glittering decoration sheet 1 may be heated by a heating means such as an infrared heater.

  Further, after the pre-molding, the glittering decorative sheet 1 may be cut in advance according to the shape of the molded product.

  The preforming die 12 is created so that the sheet outer shape is the same as the shape of the molding cavity after offsetting the thermal contraction rate and sheet thickness of the sheet, but offsetting the film thickness in the flat state. Therefore, it is difficult to finally match the cavity shape completely. That is, since a sheet having a constant film thickness is pressed against the mold, for example, when the preforming mold 12 is a convex mold, the top surface maintains a flat film thickness, but the portion below the top surface is stretched. For this reason, at least the film thickness is thin and the film thickness is partially different, and it is difficult to prepare the preforming mold 12 after strictly calculating the difference at that portion. That is, the preliminarily formed glittering decorative sheet 1 has a shape that is at least smaller than the cavity shape.

  Following the preliminary molding, the main molding is performed (see FIG. 6).

  First, the pre-molded glittering decorative sheet 1 is placed in a mold. At this time, the fixed position of the glittering decorative sheet 1 may be aligned using a phototube sensor or the like so that the design of the glittering decorative sheet 1 and the shape of the mold are aligned.

  Next, the glittering decorative sheet 1 is fixed in the mold by appropriately performing heating and suction.

  Next, the mold is closed, the molding resin is injected into the mold, and the glittering decorative sheet 1 and the molding resin are integrated.

  As the molding resin, a polyethylene resin, a polypropylene resin, an acrylic resin, a polystyrene resin, a polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin, a PC / ABS alloy resin containing glass fibers, or the like may be used. .

  After the molding resin is solidified, the mold is opened and the resin molded product 14 to which the glittering decorative sheet 1 is integrated and bonded is taken out to obtain the glittering decorative molded product 15 (see FIG. 7).

  Moreover, you may cut and remove the extra glittering decoration sheet 1 around the glittering decorative molded product 15 after the molding decoration process.

  The glittering decorative sheet 1 of the present invention is configured such that a glittering layer 3 containing at least 30 to 50% by weight of a vinyl chloride / vinyl acetate copolymer resin and a base sheet 2 are laminated to form a glittering layer. 3 is provided with flexibility, and the glittering decorative molded product 15 having a beautiful appearance can be obtained without causing cracks in the glittering layer 3 caused by pressure during injection molding.

  A transfer sheet was obtained in which a biaxially stretched polyethylene terephthalate film having a thickness of 25 μm was used as a transfer substrate, and a release layer, a release layer, a design layer, and an adhesive layer were sequentially laminated thereon.

  First, 99% by weight of a melamine resin as a resin binder and 1% by weight of a silica wax matting agent were applied on a transfer substrate by a reverse coating method, and a baking temperature of 200 ° C. and a line speed of 5 m / min. A release process was performed by baking. The coating thickness of the release layer was about 5 μm when dried.

  Next, an ink containing 91% by weight of acrylic resin and 9% by weight of silica wax matting agent was applied onto the release layer by a gravure coating method, followed by drying at a drying temperature of 80 ° C. and a line speed of 30 m / min. A release layer was formed. The coating thickness of the release layer was about 1 μm when dried.

  Next, the glitter layer was formed in the same manner as the release layer using an ink composed of a resin binder of 62 wt% acrylic resin and 38 wt% vinyl resin, and an aluminum metal pigment having an average particle diameter of 10 μm in the same amount as the resin binder. Formed. The coating thickness of the glitter layer was about 3 μm when dried.

  Next, an adhesive layer was formed in the same manner as the release layer, using an ink having a composition of 95% by weight of a vinyl chloride / vinyl acetate copolymer resin and 5% by weight of a silica wax matting agent as a resin binder. The coating thickness of the adhesive layer was about 1 μm when dried.

  Next, the transfer sheet thus obtained was transferred to a base sheet made of an ABS resin having a thickness of 100 μm by a thermal laminating method to obtain a glittering decorative sheet on which a glittering layer was formed.

  Next, the glittering decorative sheet is preformed into a plurality of concave and convex three-dimensional shapes by a pressure forming method, placed in a mold having a cavity corresponding to the shape, clamped, and molten ABS resin is injected. Then, it was cooled and solidified, and the mold was opened to obtain a glittering decorative molded product that was a key top member in which the glittering decorative sheet was integrated on the surface. The resulting glittering decorative molded product was beautiful with no cracks in its appearance.

  INDUSTRIAL APPLICABILITY The present invention can be suitably used in three-dimensional console panels, automobile interior parts such as switch bases, home appliances such as rice cookers, and mobile phone buttons, and is industrially useful.

It is sectional drawing which shows one Example of the glittering decoration sheet of this invention. It is sectional drawing which shows one Example of the glittering decoration sheet of this invention. It is sectional drawing which shows one Example of the glittering decoration sheet of this invention. It is sectional drawing which shows one Example of the transfer sheet used for manufacture of the glittering decorating sheet of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the glittering decorative molded product of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the glittering decorative molded product of this invention. It is sectional drawing which shows one Example of the glittering decorative molded product obtained by the manufacturing method of the glittering decorative molded product of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Glossy decorative sheet 2 Base sheet 3 Glossy layer 4 Surface protective layer 5 Pattern layer 6 Glossy layer adhesive layer 7 Decorative sheet adhesive layer 8 Transfer sheet 9 Transfer base material 10 Release layer 11 Release layer 12 Preliminary mold 13 Injection Mold for molding 14 Resin molded product 15 Bright decorative molded product

Claims (4)

At least a glitter layer made of ink containing a glitter pigment is formed on a thermoformable base sheet, and the glitter layer contains 30 to 50% by weight of a vinyl chloride / vinyl acetate copolymer resin, which is accompanied by stretching. A glittering decorative sheet characterized in that the glittering property is not impaired even by processing. The glittering decorative sheet according to claim 1, wherein the base sheet is composed of any one of acrylonitrile-butadiene-styrene resin, polypropylene resin, and polystyrene resin. The glittering decorative sheet according to claim 1, wherein the glittering layer contains an aluminum flake pigment. The glittering decorative sheet according to any one of claims 1 to 3 is softened by heating in advance, preliminarily molded by vacuum or compressed air, then placed in an injection mold and clamped, and then the cavity A glittering decorative molded product characterized in that a molded decorative resin is obtained by injecting a molding resin into the interior and integrating the glittering decorative sheet and the resin molded product so as not to impair the glitter of the stretched part. Manufacturing method.

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