JP2007136755A - Coextrusion molding decorative sheet and manufacturing method of coextrusion molding decorative molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achive excellent corrosion resistance with respect to a metal thin film layer in a coextrusion molding decorative sheet. <P>SOLUTION: In the coextrusion molding decorative sheet produced by forming a pattern layer, the metal thin film layer and an adhesive layer on a substrate sheet, the metal thin film layer has an island structure wherein the average interval between islands is 40-6,000 Å and has a thickness of 50-600 Å. The adhesive layer is a resin layer free of vinyl chloride resin. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

The present invention relates to a mobile phone, a video camera, a digital camera, an automobile device, a PDA (Personal Digital Assistant), a monitor for a personal computer, an electronic paper which is a light, thin and flexible electronic device such as paper, a television The present invention relates to a method for producing a molded simultaneous decorative sheet and a molded simultaneous decorative molded product used for various displays such as various electronic devices such as outdoor display electronic devices and various display members other than electronic devices.

Conventionally, a molded co-decorative sheet having a metal thin film layer is generally a co-decorated sheet in which a pattern layer, a metal thin film layer made of aluminum having a thickness of 50 to 1200 mm, and an adhesive layer are laminated on a base sheet. In many cases, the material of the pattern layer and the adhesive layer is mainly made of a vinyl chloride resin or a vinyl chloride / vinyl acetate copolymer resin (see Patent Document 1).

JP 2004-314611 A

However, in the case of a metal thin film layer formed of aluminum, since the metal thin film layer is uniform, there is a problem that cracking occurs when the co-molded decorative sheet is three-dimensionally processed with a deeply drawn shape. In addition, if the metal thin film layer is uniform, the radio wave is blocked, which causes a problem of radio wave interference. For this reason, in the case of an electronic device that communicates by sending radio waves, there is a problem that an antenna or the like must be separately installed.

Therefore, recently, a molded co-decoration sheet in which a metal thin film layer is formed using a metal in which a deposited film is formed in an island shape, specifically, indium or tin, has appeared. This is because when the metal thin film layer is formed in an island shape, radio waves can be transmitted through the gap between the islands, and the gap portion serves as a cushion and hardly causes cracks.

However, when the metal thin film layer is formed in an island shape, the surface area is larger than that of a uniform film, and the area in contact with the adhesive layer is increased. As a result, the metal thin film layer was corroded by the chlorine component released from the vinyl chloride resin contained in the adhesive layer, causing problems such as a decrease in metallic luster, discoloration, and see-through. In particular, if the thickness of the metal thin film layer was 600 mm or less, the problem of corrosion occurred in a very short time. Then, an object of this invention is to provide the manufacturing method of the shaping | molding simultaneous decorating molded article using the molding simultaneous decorating sheet which eliminated the above faults.

In order to achieve the above object, the present invention is configured as follows. That is, the present invention is a molded simultaneous decorative sheet in which at least a pattern layer, a metal thin film layer, and an adhesive layer are formed on a base sheet, wherein the metal thin film layer has an island-like structure, and an average gap between the islands and the islands Is a molded co-decoration sheet, wherein the thickness is 50 to 600 mm, and the adhesive layer is made of a non-vinyl chloride resin.

The present invention also provides a molded simultaneous decorating sheet, wherein a rear anchor layer is formed between the metal thin film layer and the adhesive layer, and the rear anchor layer is made of a non-vinyl chloride resin.

The present invention also provides a molded simultaneous decorating sheet, wherein the non-vinyl chloride resin is any of a urethane resin, an acrylic resin, a butyral resin, and a polyamide resin.

Further, the present invention provides the molded simultaneous decorating sheet, wherein the metal thin film layer is made of indium or tin.

Also, the present invention is such that the base sheet side of the co-molding decorative sheet is placed in contact with the A mold surface, and the adhesive layer side is placed so that the base sheet is in contact with the cavity surface of the B mold. And B mold are clamped, a transparent molten resin is injected into a molding space formed by the A mold and the B mold, and cooled and solidified. A method for producing a simultaneously molded decorative molded product, characterized in that a substrate is integrated to obtain a molded simultaneous decorated molded product.

Since the simultaneous decorating sheet of the present invention is characterized in that the adhesive layer is made of a non-vinyl chloride resin, there is an effect that excellent corrosion resistance is obtained. In particular, when the metal thin film layer has an island-like structure, the average gap between the islands is 40 to 6000 mm, and the thickness is 600 mm or less, the effect is remarkable.

Moreover, the simultaneous molding decorative molded product obtained using the simultaneous molding decorative sheet of the present invention has an effect of obtaining excellent corrosion resistance.

The best mode of the present invention will be described in detail with reference to the drawings. FIG. 1 is a cross-sectional view showing an embodiment of the simultaneous molding decorative sheet of the present invention. FIG. 2 is a cross-sectional view showing another embodiment of the simultaneous molding decorative sheet of the present invention. FIG. 3 is a cross-sectional view showing an embodiment of a method for producing a simultaneously decorated decorative molded product of the present invention.

In the figure, 1 is a molded decorative sheet, 2 is a base sheet, 3 is a release layer, 4 is a pattern layer, 5 is a front anchor layer, 6 is a metal thin film layer, 7 is a rear anchor layer, 8 is an adhesive layer, 9 Is a mold for molding, 10 is a simultaneously decorated decorative molded product, 11 is a release layer, 12 is a molding resin, and 13 is a transfer layer.

First, the simultaneous molding decorative sheet 1 of the present invention will be described. The simultaneous molding decorative sheet 1 is a simultaneous molding decorative sheet in which a pattern layer 4, a metal thin film layer 6, and an adhesive layer 8 are formed on at least a base sheet 2, and the metal thin film layer 6 has an island-like structure. The sheet is characterized in that the average gap between islands is 40 to 6000 mm, the thickness is 50 to 600 mm, and the adhesive layer 8 is made of a non-vinyl chloride resin. After molding, the molding simultaneous decorating sheet 1 is formed on the surface of the molding resin 12 (see FIG. 1).

Alternatively, a release layer 11 and a release layer 3 are provided between the base sheet 2 and the pattern layer 4, and after the simultaneous decorative molding, the base sheet 2 is peeled off from the interface between the release layer 11 and the release layer 3 and molded. A transfer layer 13 having only the release layer 3, the pattern layer 4, the metal thin film layer 6, the adhesive layer 8, and the like may be formed on the surface of the resin 12 (see FIG. 2). When the adhesion between the metal thin film layer 6 and the pattern layer 4 and the adhesive layer 8 is poor, the front anchor layer 5 and the rear anchor layer 7 may be provided (see FIGS. 1 and 2).

The metal thin film layer 6 has an island-like structure, and an average gap between the islands of 40 to 6000 mm and a thickness of 50 to 600 mm is applied. If the average gap between the island and the island is less than 40 mm, cracks are likely to occur and there is a problem of blocking radio waves and causing radio interference. The average gap between the island and the island exceeds 6000 mm or the thickness is less than 50 mm. In some cases, there is a problem that a metallic luster cannot be obtained. Further, when the thickness exceeds 600 mm, there is a problem that the metal thin film layer 6 is easily peeled off and corrosion is likely to occur from the side surface of the metal thin film layer 6.

In order to form the metal thin film layer 6 having an average gap between the islands of 6000 mm and a thickness of 50 to 600 mm, indium / tin / zinc may be used as the material of the metal thin film layer 6. As a method of forming the metal thin film layer 6, there are methods such as vacuum deposition, sputtering, and ion plating.

However, even if the metal thin film layer 6 is formed so that the average gap between the islands is 6000 mm and the thickness is 50 to 600 mm, the pattern layer 4 or the adhesive layer 8 in contact with the metal thin film layer 6 or the front If the anchor layer 5 and the rear anchor layer 7 are not formed from a non-vinyl chloride resin, chlorine components liberated from these layers may corrode the metal thin film layer 6. Therefore, it is important that these layers are formed from a non-vinyl chloride resin.

Non-vinyl chloride resins include polyamide resins, polyester resins, acrylic resins, polyurethane resins, polyvinyl acetal resins, polyester urethane resins, cellulose ester resins, alkyd resins, polyethylene resins, etc. In consideration of the adhesion to the metal thin film layer 6, it is preferable to select one of urethane resin, acrylic resin, butyral resin, and polyamide resin.

The pattern layer 4 is a layer for decorating the surface of the molding resin 12. As a method for forming the pattern layer 4, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. The pattern layer 4 is a pattern excluding a portion that becomes a transparent window, and is usually provided partially so as to have a frame shape or a character shape.

As the adhesive layer 8, a heat-sensitive or pressure-sensitive resin suitable for the material of the molding resin 12 is appropriately used. When the material of the molding resin 12 is an acrylic resin, a urethane resin or an acrylic resin may be used. In addition, when the material of the molding resin 12 is polyphenylene oxide / polystyrene resin, polycarbonate resin, or polystyrene blend resin, acrylic resin, polystyrene resin, polyamide resin or the like having an affinity for these resins may be used. That's fine. Examples of the method for forming the adhesive layer 8 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.

Using the simultaneous molding and decorating sheet 1 having the configuration as described above, the simultaneous molding and molding product 10 can be easily obtained using the simultaneous molding and molding method.

Next, a description will be given of a simultaneous molding and molding method by injection molding using the above-described simultaneous molding sheet 1.

In the molding simultaneous decoration molding method, first, the molding simultaneous decoration sheet 1 is fed into the molding die 9. In that case, the sheet | seat shaping | molding simultaneous decorating sheet 1 may be sent one by one, and the required part of the elongate shaping | molding simultaneous decorating sheet 1 may be sent intermittently. When using the long molding simultaneous decorating sheet 1, using a feeding device having a positioning mechanism, the registration of the pattern layer 4 of the molding simultaneous decorating sheet 1 and the molding die 9 is matched. Good. Further, when the simultaneous molding decorative sheet 1 is intermittently fed, after the position of the simultaneous molding decorative sheet 1 is detected by a sensor, the simultaneous molding decorative sheet 1 is fixed between the movable mold and the fixed mold. This is convenient because the simultaneous decorative sheet 1 can be fixed at the same position and the pattern layer 4 is not displaced.

After the molding die 9 is closed, the molding resin 12 is injected and filled into the molding die 9 from the gate, and simultaneously with the formation of the transfer object, the simultaneous molding decorative sheet 1 is adhered to the surface.

Materials for forming mold 9 include structural rolled steel, carbon steel for machine structure, carbon tool steel, alloy tool steel, high speed steel, high carbon chrome steel, bearing steel, nickel chrome molybdenum steel, chrome molybdenum steel, Aluminum chrome molybdenum steel or the like can be used. The molding die 10 can be formed by a processing method such as a milling method, a cold hobbing method, a show process method, a pressure casting method, an electroforming method, an electric discharge processing method, a corrosion processing method, an NC processing method, It can be finished to a predetermined surface roughness by polishing the surface using file dust, paper, emery powder, steel wool, rubber grindstone, felt buff or the like.

Examples of the molding resin 12 include general-purpose resins such as polystyrene resin, polyolefin resin, ABS resin, AS resin, and AN resin. Also, general engineering resins such as polyphenylene oxide / polystyrene resins, polycarbonate resins, polyacetal resins, acrylic resins, polycarbonate-modified polyphenylene ether resins, polybutylene terephthalate resins, ultrahigh molecular weight polyethylene resins, polysulfone resins, polyphenylene sulfide Super engineering resins such as resins, polyphenylene oxide resins, polyarylate resins, polyetherimide resins, polyimide resins, liquid crystal polyester resins, and polyallyl heat-resistant resins can also be used.

The shape of the molded simultaneous decorative molded product 10 may be a flat plate as a whole, or may have a two-dimensional or three-dimensional curved surface.

After the resin molded product, which is the transfer object, is cooled, the molding die 9 is opened, and the simultaneously decorated molded product 10 is taken out. Finally, the base sheet 2 of the simultaneously molded decorative sheet 1 can be peeled off and only the transfer layer 13 can be provided on the surface of the molded resin 12.

A 38 μm thick polyester film is used as a base sheet, a release layer made of an acrylic resin is formed thereon, a pattern layer made of an acrylic resin is formed thereon, and a front anchor made of an acrylic-urethane resin is formed thereon. A layer was formed. Next, a metal thin film layer made of indium having an average gap between islands of 10 to 7000 mm and a thickness of 20 to 800 mm was formed on the surface of the front anchor layer by vacuum deposition.

Next, an adhesive layer made of a urethane resin is formed on the surface of the metal thin film layer to obtain a simultaneous molding decorative sheet, the simultaneous molding decorative sheet is placed in a molding die, the mold is closed, and an acrylic type After the molding resin was injected and cooled, the molding die was opened, and the molded and simultaneously decorated molded product was taken out. Finally, the base sheet of the simultaneous molding decorative sheet was peeled off, and only the transfer layer was provided on the acrylic molding resin surface.

When the molded simultaneous decorative molded product thus obtained was left under high temperature and high humidity of 60 ° C. and 95%, the average gap between the islands was 40 to 7000 mm and the thickness was 30 to 600 mm. Showed very good corrosion resistance (see Table 1).

However, when the adhesive layer was made of vinyl chloride resin, the corrosion resistance was greatly reduced. When tested with various adhesive layers and molding resins, molded co-decoration sheets consisting of adhesive layers containing chlorine components such as chlorinated rubber resins, chlorinated polypropylene resins, and vinyl chloride-vinyl acetate resins are vinyl chloride resins. In addition to the urethane resin, acrylic resin, butyral resin, polyamide resin, etc. maintained excellent corrosion resistance (see Table 2).

A polycarbonate film having a thickness of 50 μm was used as a base sheet, a pattern layer made of an acrylic resin was formed thereon, and a front anchor layer made of an acrylic-urethane resin was formed thereon. Next, a metal thin film layer made of tin having an average gap between islands of 10 to 6000 mm and a thickness of 20 to 800 mm was formed on the surface of the front anchor layer by vacuum deposition.

Next, after forming a rear anchor layer made of urethane resin on the surface of the metal thin film layer and forming an adhesive layer made of polyamide resin on it to obtain a molded simultaneous decorative sheet, the molded simultaneous decorative sheet is After placing in the molding die, closing the die, injecting a polyamide-based molding resin and cooling, the molding die was opened and the simultaneously decorated decorative molded product was taken out. The obtained simultaneously molded decorative product was obtained by providing a simultaneous molded decorative sheet on the surface of the polyamide-based molded resin.

When the molded simultaneous decorative molded product thus obtained is left under high temperature and high humidity of 60 ° C. and 95%, the average gap between the islands is 30 to 6000 mm and the thickness is 50 to 800 mm. Showed very good corrosion resistance (see Table 3).

However, when the adhesive layer was made of a vinyl chloride resin, the corrosion resistance was significantly reduced as in Example 1. When the adhesive layer and the molding resin were changed in various ways and tested, a molded co-decorated sheet consisting of an adhesive layer containing a chlorine component such as a chlorinated rubber resin, a chlorinated polypropylene resin, or a vinyl chloride-vinyl acetate resin was found to be vinyl chloride. As in Example 1, the corrosion resistance similar to that of the resin is significantly decreased, and the acrylic resin, butyral resin, polyamide resin, etc. in addition to the urethane resin maintain excellent corrosion resistance. (See Table 4).

It is sectional drawing which shows one Example of the shaping | molding simultaneous decorating sheet of this invention. It is sectional drawing which shows another one Example of the shaping | molding simultaneous decorating sheet of this invention. It is sectional drawing which shows one Example of the manufacturing method of the simultaneous decoration decoration molded product of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molding simultaneous decoration sheet 2 Base sheet 3 Peeling layer 4 Picture layer 5 Front anchor layer 6 Metal foil film layer 7 Rear anchor layer 8 Adhesive layer 9 Mold for molding 10 Molding simultaneous decoration molding product 11 Release layer 12 Molding resin 13 Transfer layer

Claims (5)

  A molded decorative sheet in which at least a pattern layer, a metal thin film layer, and an adhesive layer are formed on a base sheet, wherein the metal thin film layer has an island-like structure, and an average gap between the islands and the islands is 40 to 6000 mm A simultaneously molded decorative sheet, wherein the thickness is 50 to 600 mm, and the adhesive layer is made of a non-vinyl chloride resin.   The molded simultaneous decorating sheet according to claim 1, wherein a rear anchor layer is formed between the metal thin film layer and the adhesive layer, and the rear anchor layer is made of a non-vinyl chloride resin.   3. The simultaneously decorated decorative sheet according to claim 1 or 2, wherein the non-vinyl chloride resin is any one of urethane resin, acrylic resin, butyral resin, and polyamide resin.   The material for the metal thin film layer is indium or tin, and the simultaneously decorated decorative sheet according to any one of Items 1 to 3.   The base sheet side of the simultaneously molded decorative sheet according to any one of Items 1 to 4 is set in contact with the A mold surface, and the adhesive layer side is set in contact with the cavity surface of the B mold. The mold A and the mold B are clamped, a transparent molten resin is injected into a molding space formed by the mold A and the mold B, and after cooling and solidifying, the above-mentioned simultaneous decorative sheet And a transparent resin base material are integrated to obtain a simultaneously molded decorative molded product.

Images