JP2006281740A - Sheet for decorative molded article, decorative molded article, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive and lightweight sheet of a decorative molded article, which can give classy feeling, metallic luster, high quality sense and the like similar to those of a metalware, to an molded article, and, at the same time, can expand the choice of materials in manufacturing, is hardly scratched, and can suppress the risk that it damages the environment, a decorative molded article, and its manufacturing method. <P>SOLUTION: The molded article is obtained by pressure forming the sheet 1 for the decorative molded article to a substantially hat-shape in the cross-section to form a fine embossed-pattern 6 for decoration on an outer peripheral portion of its ceiling concentrically, and by housing a resin 7 in a hollow part of the sheet 1 for the decorative molded article to integrate. The sheet 1 for the decorative molded article is formed by a light transmissive film layer 2 having a flexibility, and a decorative layer 3 integrated by at least the lamination of the metal thin film layer 4 on the film layer 2. The formation of the embossed-pattern 6 on the sheet 1 for the decorative molded article projecting the high quality sense increases the decorativeness, and since the decorative molded article is manufactured by integrating the sheet 1 for the decorative molded article and the resin 7, a weight saving, an improvement in operability, and cost reduction can be achieved. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention is used for decorative molded products that can be used for molded products constituting optical devices, communication devices, household electrical appliances, automobiles, etc., and can impart a high-class feeling, high quality, gloss, texture, etc. similar to metal products. The present invention relates to a sheet, a decorative molded product, and a manufacturing method thereof.

  High-grade types such as optical equipment, communication equipment, home appliances, and automobiles may be required to have a high-class feeling, metallic luster, and fine texture peculiar to metals in order to satisfy user satisfaction and superiority based on ownership. As means for realizing such a high-class feeling, metallic luster, and high quality, the formation of the grinding grooves 30 can be mentioned in addition to the use of plating treatment and titanium exterior. The grinding grooves 30 are formed concentrically on the surface of the shutter lid 32 formed on the disk of the compact camera 31 shown in FIG. 8, for example, so that the compact camera 31 has a high-class feeling, metallic luster, Gives a fine texture.

In the case of forming such a grinding groove 30, conventionally, a method of actually forming the grinding groove 30 in a metal product such as aluminum (see Patent Document 1) or a molded product having the same shape as the metal product is injection molded. And the method of plating the surface is employ | adopted (refer patent document 2).
JP 2004-42142 A JP 2003-183880 A

Since the conventional method of forming the grinding groove 30 has been performed as described above, there are the following problems.
First, when the grinding groove 30 is actually formed on a metal product that is more expensive than a molded product, there is a problem that the mass is large, labor is required, and the cost is increased.

  In addition, when a molded product having the same shape as that of a metal product is molded and the surface thereof is plated, the resin that can be plated is limited to a part of the resin such as ABS resin. There is a problem that it becomes narrow and easily damaged. Furthermore, if a wet plating method is employed in the plating process, there is a high possibility that the waste liquid will damage the environment.

  The present invention has been made in view of the above, and can give a molded product a high-class feeling similar to that of a metal product, a metallic luster, a high-quality texture, etc. And it aims at providing the cheap and lightweight sheet | seat for decorative molded products which can suppress the possibility of impairing an environment, a decorative molded product, and its manufacturing method.

In the present invention, in order to solve the above-described problem, a decorative molded product is formed by thermoforming into a three-dimensional shape having a hollow portion and then integrating and integrating the resin in the hollow portion. There,
Including a flexible light-transmitting resin layer and a decorative layer in which at least the metal thin film layer is laminated (stacked) on the resin layer, and at least a part of the laminated region of the metal thin film layer in the resin layer, A feature is that a concavo-convex pattern for decoration is formed.

In the present invention, in order to solve the above-mentioned problem, the decorative molded product sheet is thermoformed into a three-dimensional shape, and a resin is built in and integrated in the hollow portion of the decorative molded product sheet. Obtained by
A decorative molded product sheet is formed from a flexible light-transmitting resin layer and a decorative layer in which at least a metal thin film layer is laminated on the resin layer, and the sheet for decorative molded product is formed during thermoforming. A decorative uneven pattern is formed on at least a part of the laminated region of the metal thin film layer.
In addition, a decoration layer can be formed from the metal thin film layer laminated | stacked on a resin layer, and the visually recognizable color pattern layer formed in any one of these resin layers and a metal thin film layer.

In the present invention, in order to solve the above-mentioned problem, the decorative molded product sheet is thermoformed into a three-dimensional shape to form a decorative uneven pattern on at least a part of the decorative molded product. A manufacturing method in which a resin is incorporated in a hollow portion of a sheet for integration,
The decorative molded product sheet is formed from a flexible light-transmitting resin layer and a decorative layer in which at least a metal thin film layer is laminated on the resin layer, and the metal in the decorative molded product sheet It is characterized in that at least a part of the laminated region of the thin film layer is overlapped with the concavo-convex pattern.

  Here, the three-dimensional shape having the hollow portion in the claims includes at least a substantially C-shaped section, a U-shape, a V-shape, an Ω-shape, a hat shape, and the like. Thermoforming includes pressure forming (also referred to as compressed air forming), vacuum forming, and pressure forming. Moreover, the sheet | seat for decorating molded articles should just be formed from a resin layer and a decorating layer, and may have a several adhesive layer and protective layer in addition to this. The resin layer does not particularly require the presence or absence of a preform, and may be either transparent or translucent.

  The decorative layer only needs to have a plurality of thin metal layers having light reflectivity, and may have a color pattern layer or a reflective layer having colors such as red, blue, green, yellow, and black. good. The concavo-convex pattern for decoration is a polka dot pattern, turtle shell connection pattern, scale connection pattern, scale connection pattern, rhombus pattern, concentric pattern, rhombus in front view or planar view using a plurality of concave (including groove) protrusions. Patterns, patterns similar to these, symbols, characters, etc. are formed. Further, the decorative molded product is used as all or part of at least an optical device, a communication device including a mobile phone, an OA device including a key top, a home appliance, an automobile, an indoor decorative body, a can, and the like.

  According to the present invention, a concavo-convex pattern is preformed on a decorative molded product sheet including a decorative layer, and at least a part of the metal thin film layer is superimposed on the concavo-convex pattern. A decorative molded product is manufactured by integrating a decorative molded product sheet and a resin. In the decorative molded product manufactured in this way, at least the concavo-convex pattern with the metal thin film layer as a base brings out a high-class feeling, metallic luster, fine texture and the like.

  According to the present invention, it is possible to give a molded product a high-class feeling similar to that of a metal product, a metallic luster, a fine texture, and the like, while expanding the range of material selection during production and effectively suppressing the risk of damaging the environment. There is an effect that can be done. In addition, the molded product can be hardly damaged.

  In addition, since a thermoforming method is used as a method of forming a decorative molded product sheet in a three-dimensional shape, a thin molded product can be obtained compared to the projected area of the sheet, and the molding pressure is low. Therefore, the cost of the mold is low and the number of production days can be shortened. Moreover, since it can print on the sheet | seat for decorative molded products, it becomes possible to obtain a multicolor printed molded product.

  Further, if the decorative layer is formed of a metal thin film layer laminated on the resin layer and a visible color pattern layer formed on one of the resin layer and the metal thin film layer, the metal thin film layer and the unevenness are formed. The decorativeness can be further improved by a synergistic effect of the high quality, metallic luster, fine texture, etc. created by the pattern and the color of the color pattern layer.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described with reference to the drawings. A decorative molded product according to the present embodiment has a substantially hat-shaped cross section as shown in FIGS. The concave / convex pattern 6 is formed concentrically on the outer peripheral portion of the ceiling, in other words, the most visually recognizable portion, and the resin 7 is incorporated in the hollow portion of the decorative molded product sheet 1. The operation key 10 is obtained by integrating them, and the decorative molded product sheet 1 is visible on the transparent film layer 2 and laminated on the film layer 2 so as to give the decorative pattern 6 a decorative property. The decorative layer 3 is formed in a multilayer structure.

  As shown in FIG. 1, the film layer 2 is formed into a thin film having flexibility and light transmittance using a resin such as polyethylene terephthalate, polycarbonate, polypropylene, polyethylene, polystyrene, acrylic, ABS, or the like. This film layer 2 is formed to a thickness of 10 to 500 μm, preferably 25 to 200 μm. This is because when the thickness of the film layer 2 is less than 10 μm, the film layer 2 is too thin to obtain a high-quality decorative molded product. On the contrary, if the thickness of the film layer 2 exceeds 500 μm, there is a possibility that it is not possible to cope with a small, light and thin electronic device, and it is not possible to reduce the cost.

  As shown in FIG. 1, the decorative layer 3 is laminated on the film layer 2 to form a visible metal thin film layer 4 that forms a pseudo metal surface, and is partially formed on the film layer 2 to form the film layer 2 and the metal. A visible color pattern layer 5 interposed between the thin film layer 4 and the thin film layer 4 is formed. For example, the metal thin film layer 4 is thinly formed on a portion excluding the center of the ceiling of the operation key 10, in other words, on a portion where the uneven pattern 6 is formed. The metal thin film layer 4 has a concavo-convex thickness of about 200 to 800 angstroms by a vacuum deposition method or a sputtering method using metal powder made of, for example, Al, In, Ni, Sn, Cr, Ti, Au, Ag, Cu or the like. It is formed in a thin film and expresses a metal color peculiar to metals.

  The method for forming the metal thin film layer 4 is not limited to the above, and it can also be formed by thermally transferring a transfer foil to the film layer 2, and when it is desired to reduce costs, the metal powder is added to the binder. A metallic ink can be prepared by dispersing it, and this metallic ink can be formed simply and inexpensively by screen printing, gravure printing, offset printing or the like.

  The color pattern layer 5 is formed, for example, as a pattern having various colors on the center of the ceiling of the operation key 10, in other words, the non-formed portion of the uneven pattern 6, and through the film layer 2, a high-class feeling, high quality, texture, etc. To produce. The color pattern layer 5 is formed, for example, by subjecting the film layer 2 to wet processing such as a screen printing method, a gravure printing method, and an offset printing method using various inks made of translucent ink. Of course, the method for forming the color pattern layer 5 is not limited to this, and it can also be formed by thermal transfer such as hot stamping using a thermal transfer sheet. Further, the color pattern layer 5 can be formed on the film layer 2 but can also be formed on the metal thin film layer 4.

  In the above, when manufacturing the sheet | seat 1 for decorative molded products, while forming the color pattern layer 5 in the transparent film layer 2 by screen printing etc., the formation plan part of the uneven pattern 6 in the film layer 2 If the metal thin film layer 4 is formed by a vacuum deposition method or the like to obtain a metallic luster peculiar to the metal, the decorative molded product sheet 1 can be manufactured. When forming the metal thin film layer 4, after forming a metal thin film on the entire surface of the film layer 2, the metal thin film may be partially etched to form the metal thin film layer 4. Alternatively, vapor deposition may be performed.

  Next, when manufacturing the operation key 10 which is a decorative molded product using the decorative molded product sheet 1, first, the manufactured decorative molded product sheet 1 is preheated, and this decorative molding is performed. The product sheet 1 is set in a mold and subjected to pressure forming or vacuum forming, and the decorative molded product sheet 1 is bent into a substantially bottomed cylinder having a substantially hat-shaped cross section, in other words, the outer periphery of the ceiling, in other words, A fine uneven pattern 6 for decoration is formed in a concentric circle in a plan view on a portion laminated on the metal thin film layer 4 (see FIGS. 2 and 3).

  As long as the forming method is a thermoforming method, either a pressure forming method or a vacuum forming method may be used, but the pressure forming method increases the forming pressure compared to the vacuum forming method, and improves the reproducibility of the shape. A deep-drawn molded product can be obtained. In addition, when the film layer 2 of the decorative molded product sheet 1 is a biaxially stretched polypropylene or polystyrene film, a large shrinkage force acts upon heating, but according to the pressure forming method, the shrinkage force is overcome and stretched. Can be made.

  The fine concavo-convex pattern 6 for decoration is formed by transferring the fine concavo-convex pattern formed on the mold. The fine concavo-convex pattern of this mold consists of concave parts, convex parts, and grooves that are ground into the mold. From the viewpoint of ensuring transfer, the surface roughness of JIS B0601-2001 has a roughness of Ra 0.5 μm or more. preferable.

  When the decorative molded product sheet 1 is molded into the shape of the operation key 10 with the uneven pattern 6, the resin 7 serving as a core material is built in the hollow portion of the molded decorative molded product sheet 1. If it integrates with the decoration layer 3, the operation key 10 with the uneven | corrugated pattern 6 backed by the metal thin film layer 4 can be manufactured (refer FIG. 3). As a method of integrating and integrating the resin 7, there are an injection molding method in which a molten thermoplastic resin is injected and cured, a method in which a photocurable resin is dropped and then irradiated with light such as ultraviolet rays, and a hard resin. And a method of bonding with an adhesive.

  The thermoplastic resin used for injection molding is not particularly limited. For example, ABS, AS, styrene, vinyl chloride, acrylic, polycarbonate, PC / ABS alloy resin, polyethylene And polyolefin resins such as polypropylene, polybutene, polymethylpentene, ethylene-propylene polymerization, ethylene-propylene-butene copolymer, and olefinic thermoplastic elastomers. A corresponding pattern is formed in advance on the injection mold.

  According to the above, the decorative grooved sheet 1 with the decorative layer 3 that gives a sense of quality and quality is not formed on the expensive metal product, rather than actually forming the grinding groove 30 over time. Since it is molded into a preformed product with 6 to further enhance the decorating properties, and then this preformed product and the resin 7 are integrated to produce a decorated molded product, luxury, high quality, gloss, texture, etc. It is possible to reduce weight, improve workability, and reduce costs while securing the above.

  Further, since there is no need to perform plating on the surface of the molded product, the range of selection of the resin material during production can be remarkably increased, and the operation key 10 that is not easily damaged can be obtained. Furthermore, since the wet plating method can be omitted, there is no possibility that the waste liquid will damage the environment.

Next, FIG. 4 shows a second embodiment of the present invention. In this case, a heat-resistant protective layer 8 having a backup function is applied to the metal thin film layer 4 of the decorative layer 3 by hot melt lamination or the like. The resin 7 serving as a core material is integrated into the interior of the decorative molded product sheet 1 by an injection molding method.
As the heat-resistant protective layer 8, various thermoplastic resin films having heat resistance are used. Specifically, acrylic, polycarbonate, and ABS resin 7 films that are excellent in processability, decorating properties, and mechanical properties are used.

  The protective layer 8 is formed to a thickness of 25 to 500 μm and has a glass transition temperature (Tg) in the range of 60 to 160 ° C. This is because if the thickness of the protective layer 8 is less than 25 μm, it cannot withstand the heat of injection molding, and conversely if it exceeds 500 μm, the heat during the preform before injection molding is not sufficiently transmitted. This is because cracks and wrinkles may occur in the metal thin film layer 4.

  In addition, when the glass transition temperature (Tg) is less than 60 ° C., the protective layer 8 is easily deformed and damaged by the melted resin 7, and conversely, when it exceeds 160 ° C., the pre-injection molding is performed. This is because the heating time cannot be shortened. The other parts are the same as those in the above embodiment, and the description thereof is omitted.

  Also in this embodiment, the same effect as the above embodiment can be expected, and the protective layer 8 effectively protects the decorative layer 3 from the heat of the molten resin 7, so the injection molding method is used from the viewpoint of mass production. Even if it is adopted, it is clear that microcracks and wrinkles are generated in the decorative layer 3 and can be effectively suppressed and prevented from functioning.

  Next, FIGS. 5 to 7 show a second embodiment of the present invention. In this case, air is applied to the mold 20 when the decorative molded product sheet 1 is subjected to pressure forming or vacuum forming. A plurality of air grooves 21 serving as flow passages are formed, the concavo-convex pattern 6 is used as a plurality of arrow symbols, and the decorative molded product is used as a navigation button of a mobile phone.

The air groove 21 is formed between, for example, a concave portion and a concave portion forming the concave / convex pattern 6 or between the convex portion and the convex portion, or is formed in communication with the bottom of the plurality of concave portions, and is connected to a vacuum (not shown). Is done. Other parts are the same as those in the above embodiment, and thus the description thereof is omitted.
In this embodiment, the same effect as that of the above embodiment can be expected, and a plurality of air grooves 21 are punched in the mold 20 together with the concavo-convex pattern 6, and the decorative molded product sheet 1 is formed by blowing air or exhausting air. Obviously, it is possible to easily make the molding 20 remarkably efficient because it can be easily brought into close contact with the mold 20 and the heating plate.

  In the above embodiment, the decorative layer 3 is laminated on the film layer 2, but a transparent adhesive layer may be interposed between the film layer 2 and the decorative layer 3 to obtain a strong adhesive structure. . Further, although the protective layer 8 is simply laminated on the metal thin film layer 4, an adhesive layer may be adhered to the protective layer 8, and the resin 7 injected to the adhesive layer may be adhered to obtain a strong adhesive structure. .

It is sectional explanatory drawing which shows the state before the partial etching in embodiment of the sheet | seat for decorative molded products which concerns on this invention. It is plane explanatory drawing which shows embodiment of the sheet | seat for decorative molded products which concerns on this invention, a decorative molded product, and its manufacturing method. It is sectional explanatory drawing which shows embodiment of the sheet | seat for decorative molded products which concerns on this invention, a decorative molded product, and its manufacturing method. It is sectional explanatory drawing which shows 2nd Embodiment of the sheet | seat for decorative molded products which concerns on this invention. It is plane explanatory drawing which shows 3rd Embodiment of the sheet | seat for decorative molded products which concerns on this invention, a decorative molded product, and its manufacturing method. FIG. 6 is a cross-sectional explanatory view of FIG. 5. It is sectional explanatory drawing which shows the metal mold | die in 3rd Embodiment of the manufacturing method of the decorative molded product which concerns on this invention. It is front explanatory drawing which shows the cutting groove formed in the concentric circle on the shutter cover of a compact camera.

Explanation of symbols

1 Sheet for decorative molded product 2 Film layer (resin layer)
3 decorative layer 4 metal thin film layer 5 colored pattern layer 6 uneven pattern 7 resin 8 protective layer 10 operation key (decorated molded product)
20 Mold

Claims (4)

After being thermoformed into a three-dimensional shape having a hollow part, a decorative molded product sheet that forms a decorative molded product by incorporating and integrating a resin in the hollow part,
A flexible light-transmitting resin layer and a decorative layer on which at least a metal thin film layer is laminated on the resin layer, and at least a part of the laminated region of the metal thin film layer in the resin layer are used for decoration A sheet for decorative molded product, characterized in that an uneven pattern is formed. A decorative molded product obtained by thermoforming a decorative molded product sheet into a three-dimensional shape and incorporating and integrating a resin in the hollow portion of the decorative molded product sheet,
A decorative molded product sheet is formed from a flexible light-transmitting resin layer and a decorative layer in which at least a metal thin film layer is laminated on the resin layer, and the sheet for decorative molded product is formed during thermoforming. A decorative molded product, wherein a decorative concavo-convex pattern is formed on at least a part of the laminated region of the metal thin film layer.   The decorative molded product according to claim 2, wherein the decorative layer is formed from a metal thin film layer laminated on the resin layer, and a visible color pattern layer formed on one of the resin layer and the metal thin film layer. . The decorative molded product sheet is thermoformed into a three-dimensional shape, and a decorative uneven pattern is formed on at least a part of the decorative molded product sheet, and a resin is incorporated in the hollow portion of the decorative molded product sheet and integrated. A method of manufacturing a decorative molded product,
The decorative molded product sheet is formed from a flexible light-transmitting resin layer and a decorative layer in which at least a metal thin film layer is laminated on the resin layer, and the metal in the decorative molded product sheet A method for producing a decorative molded product, wherein at least a part of a laminated region of a thin film layer and an uneven pattern are overlapped.

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