JP2007331185A - Method for producing multilayer resin molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To produce a multilayer resin molding without the occurrence of a fault such as cracking or whitening, for example, in an angular part or a bent part between two surfaces by using a protective film having a protective resin layer. <P>SOLUTION: The protective film 10 in which the transparent protective resin layer is laminated on one side of a plastic film is heated at 100-140°C and arranged in an air pressure mold 30, and heated compressed air of 200-300°C and 8-15 MPa is charged into an air pressure box 40 combined with the air pressure mold 30 to form a molded protective film 15 molded in a mold surface shape. The molded protective film 15 is arranged in an injection molding mold to make the protective resin layer 12 turn to one mold surface of the injection molding mold. By film insert injection molding, the multilayer resin molding in which the molded protective film and a substrate are integrated is produced. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a multilayer resin molded article, and in particular, after forming a protective film provided with a protective resin layer on the surface, the multilayer resin is obtained by film insert injection molding (also referred to as insert film injection molding). The present invention relates to a method of manufacturing a molded article.

  Conventionally, multilayer resin molded products with a plastic film provided on the surface of resin molded products for the purpose of decorativeness and protection are automotive interior parts such as automotive air conditioner operation parts and shift lever operation parts, keyless entry key case parts, It is used for the window frame part of the liquid crystal display part of a mobile phone, various cases, and the like. As a method for producing such a multilayer resin molded product, film insert injection molding is used (see Patent Document 1).

  Film insert injection molding is a multilayer resin in which a plastic film is set in an injection mold, a base material resin is injected into the injection mold, the base material is laminated on the plastic film, and the plastic film and the base material are integrated. This is a method for obtaining a molded product.

  In addition, for reasons such as improving the scratch resistance of the surface of multilayer resin molded products, film insert injection molding is performed using a protective film having a protective resin layer (hard coat layer) on the surface, so that it can be flat or gently curved. It has been proposed to manufacture panels and automobile windows (see Patent Documents 2 and 3). As shown in Patent Documents 2 and 3, the protective resin layer (hard coat layer) is coated with an ultraviolet curable or thermosetting hard coat agent on the surface of the plastic film, and then dried and cured. Formed. Examples of the UV curable hard coating agent include radical polymerizable hard coating agents such as unsaturated polyester resins and acrylic resins, and cationic polymerizable hard coating agents such as epoxy and vinyl ether types, and thermosetting types. Examples of the hard coat agent include silicone-based and melamine-based agents.

  However, since the protective film having a protective resin layer has high rigidity due to the presence of the protective resin layer (hard coat layer), an attempt is made to form it into a three-dimensional shape by conventional vacuum forming or pressure forming (including vacuum / pressure forming). Then, there existed a problem which produces malfunctions, such as a crack and whitening, in a deformation | transformation site | part. In particular, defects such as cracks and whitening were likely to occur at corners (corner portions) and bent portions between two surfaces. Therefore, in the conventional method for producing a multilayer resin molded product, the base film is injection-molded by placing the protective film in an injection mold without shaping it into a three-dimensional shape. There is a problem that only a multilayered resin molded article can be obtained satisfactorily.

JP 2005-178062 A JP 2005-280122 A JP 2001-205726 A

  The present invention has been made in view of the foregoing points, and uses a protective film having a protective resin layer to form a multilayer resin molding without causing defects such as cracks and whitening at corners and bent portions between two surfaces. The purpose is to be able to manufacture products.

  In the invention of claim 1, a protective film in which a transparent protective resin layer is laminated on one side of a plastic film is heated to 100 to 140 ° C. and arranged in a compressed air type, and 200 to 200 in a compressed air box combined with the compressed air type. A protective film shaping step of obtaining a shaped protective film shaped into the shape of the mold surface by blowing heated compressed air at 300 ° C. and 8 to 15 MPa to bring the protective film into close contact with the mold surface of the compressed air mold, The shaping protective film is placed in the injection mold so that the protective resin layer side faces one mold surface of the injection mold, and the substrate resin is injected into the injection mold to protect the shaping. A multilayer resin molded product in which the shaped protective film and the base material are integrated can be obtained by a film insert injection molding process in which a base material is laminated on the opposite side of the protective resin layer of the film. According to a method for manufacturing a multilayer resin molded article characterized by.

  According to a second aspect of the present invention, in the first aspect, the protective film has a surface printing layer partially formed on a surface of the protective resin layer.

  According to a third aspect of the present invention, the protective film according to the first aspect is characterized in that the plastic film is transparent, and an inner surface printing layer is formed on a surface opposite to the protective resin layer.

  According to a fourth aspect of the present invention, in the third aspect, a surface printing layer is partially formed on the surface of the protective resin layer, and the inner surface printing layer is not covered with the surface printing layer. .

  According to a fifth aspect of the present invention, in the first aspect, the protective film includes the transparent plastic film and a light-transmitting portion and a light-impermeable portion on a surface opposite to the protective resin layer. In the film insert injection molding step, a transparent first substrate resin is injected into the injection mold in which the shaped protective film is disposed, and the shaped protective film is formed. A transparent first base material that covers the inner surface printed layer is laminated on a surface opposite to the protective resin layer, and after forming the first base material, the light transmittance of the inner surface printed layer in the injection mold The second base material is laminated on the first base material without covering the light transmissive part of the inner surface printed layer by injecting the resin for the second base material except for the portion or the light transmissive part and its periphery. The first base and the second base And forming a timber.

  A sixth aspect of the present invention provides the protective film according to the first aspect, wherein the plastic film is transparent, and a surface printing layer is partially formed on the surface of the protective resin layer, which is opposite to the protective resin layer. The film insert injection comprising: an inner surface printed layer comprising a light transmissive portion and a light impermeable portion on the side surface; and the light transmissive portion is not covered with the surface printed layer. In the molding step, a transparent first substrate resin is injected into the injection mold in which the shaped protective film is disposed, and the inner surface printing is performed on the surface of the shaped protective film opposite to the protective resin layer. A transparent first base material covering the layers is laminated, and after forming the first base material, the second base is formed in the injection mold except for the light-transmitting portion of the inner surface printing layer or the light-transmitting portion and its periphery. By injecting resin for materials A second substrate is laminated on the first substrate without covering the light-transmitting portion of the inner surface printed layer to form a substrate composed of the first substrate and the second substrate. .

  According to the invention of claim 1, a protective film in which a transparent protective resin layer is laminated on one side of a plastic film is heated to 100 to 140 ° C. and disposed in a compressed air type, and is placed in a compressed air box combined with the compressed air type. Since the formed protective film shaped into the mold surface shape is formed by blowing heated compressed air of 200 to 300 ° C. and 8 to 15 MPa to bring the protective film into close contact with the compressed air mold surface. It is difficult to cause defects such as cracks and whitening at the corners of the film and the bent part between the two surfaces, and the shaped protective film obtained by this is placed in the injection mold and the substrate is injection molded, so the surface A multi-layered resin molded article with a good aesthetic appearance that does not have defects such as cracks or whitening in the protective film at the corners or bent portions between the two surfaces can be obtained.

  According to invention of Claim 2, since the said protective film consists of a surface printing layer partially formed in the surface of the protective resin layer, the multilayer resin molded product which improved the decorating property by the surface printing layer is manufactured. can do. For example, it is possible to produce a highly decorative multilayer resin molded article in which a surface printing layer made of matte printing is provided on a part of the surface of the glossy protective resin layer.

  According to invention of Claim 3, since the said plastic film becomes transparent and the inner surface printing layer is formed in the surface on the opposite side to the said protective resin layer, the said protective film has a transparent protective resin layer interposed between them. A high multilayer resin molded product that can be seen through the inner surface printed layer can be manufactured.

  According to the invention of claim 4, since the surface print layer is partially formed on the surface of the protective resin layer and the inner surface print layer is not covered with the surface print layer, the surface print layer is used for decorativeness. In addition, it is possible to manufacture a multilayer resin molded product that can see through the inner surface printed layer through a transparent protective resin layer.

  According to invention of Claim 5 and 6, the multilayer which can light (light-emit) the light transmissive part of the said inner surface printing layer by illuminating the part which is not covered with the said 2nd base material with an illuminating device. A resin molded product can be manufactured. Moreover, in the portion not covered with the second base material, the transparent first base material is laminated on the shaping protective film and is reinforced with backing, so that it is bent or damaged when the multilayer resin molded product is used. Can be suppressed. Further, the transparency and color unevenness of the protective resin layer that may occur during injection molding of the substrate can be made inconspicuous due to the presence of the transparent first substrate. Furthermore, according to the invention of claim 6, the decorativeness of the multilayer resin molded product can be further enhanced by the surface printed layer provided at a position not covering the light transmitting portion of the inner surface printed layer.

  Embodiments of the present invention will be described below. FIG. 1 is a partial cross-sectional view of a protective film in the first embodiment of the present invention, FIG. 2 is a schematic diagram of a protective film shaping process in the first embodiment, and FIG. 3 is a schematic diagram of a film insert injection molding process in the same embodiment. It is.

  The manufacturing method of the multilayer resin molded product of 1st Embodiment consists of a protective film shaping | molding process and a film insert injection molding process.

  As shown in FIG. 1, the protective film 10 used in the protective film shaping step is composed of a plastic film 11 having a protective resin layer (hard coat layer) 12 laminated on one side, and is entirely transparent. Yes. In addition, “transparent” in the present invention includes both colorless and transparent cases.

  The said plastic film 11 comprises a film base material in the said protective film 10, and is comprised by transparent resin in this embodiment. The resin constituting the plastic film 11 is not particularly limited as long as it has good shapeability, film insert injection moldability, and the like. For example, polyolefin resin, polyester resin, polystyrene resin, polyamide resin, polyimide resin, acrylic resin, polycarbonate resin, and the like can be given. In particular, a polycarbonate resin or a polyethylene terephthalate resin is preferable in terms of transparency and heat resistance. Moreover, since the shaping property will fall if the thickness of the said plastic film 11 is too thick, and intensity | strength will fall if it is too thin, it is set as the optimal thickness in consideration of them. An example of a preferable range is 100 to 500 μm.

  The protective resin layer (hard coat layer) 12 is formed by applying the ultraviolet curable or thermosetting hard coat agent shown in the background art by a known coating method or dipping method, and drying and curing. It is considered transparent. The hard coat agent is preferably the ultraviolet curable type from the viewpoints of curability and manufacturability. The coating method is not particularly limited, and examples thereof include direct gravure roll coating, gravure roll coating, and kiss coating. If the thickness of the protective resin layer 12 is too thick, it becomes difficult to form, and if it is too thin, the surface protection function such as scratch resistance is lowered, and the optimum thickness is considered in consideration of the formability and the surface protection function. It is said. Preferably, the thickness after curing is 2 to 5 μm, and in relation to the thickness of the plastic film 11, it is 0.5% to 2% of the thickness of the plastic film 11, more preferably 0.5 to 1.1. %.

  In the protective film shaping step, first, as shown in FIG. 2 (2-A), the protective film 10 is heated by a heating device 25 such as a heater to be deformable. The heating temperature of the protective film 10 is a temperature at which the protective film 10 can be deformed, and is preferably 100 to 140 ° C. When the temperature is lower than 100 ° C., it becomes difficult to form at the time of shaping by a subsequent compressed air type, or the protective resin layer 12 is likely to be cracked or whitened at a bent deformation portion. On the other hand, when the temperature is higher than 140 ° C., the protective film 10 is partially stretched and weakened at the time of forming by the compressed air mold, or the protective resin layer is transparent between the stretched portion and other portions. And changes in color, etc., and the beauty is easily lost.

  Next, as shown in FIG. 2 (2-B), the heated protective film 10 is disposed in the compressed air mold 30, and then the compressed air mold 30 is combined with a compressed air box 40 and covered. Both ends of the protective film 10 are clamped by the compressed air box 40, and the sandwiched portions of the protective film 10 are stretched in the compressed air mold 30. At this time, in the present embodiment, the protective resin layer 12 is disposed so as to face the mold surface 31 of the compressed air mold 30. The “pressure type” in the present invention includes a vacuum pressure type. The compressed air mold 30 and the compressed air box 40 are used for known compressed air forming (including vacuum / pressure forming). Further, the compressed air mold 30 has a mold surface 31 whose inner surface is matched to the outer surface shape of the multilayer resin molded product, and a discharge hole 32 is formed through the mold surface 31 and outside the mold. On the other hand, the compressed air box 40 is configured to cover the compressed air mold 30, and an air blowing hole 41 is formed through the inside and outside of the compressed air box 40 in the center of the upper surface.

  Thereafter, heated compressed air is blown into the compressed air box 40 from the air blowing holes 41 of the compressed air box 40 to bring the protective film 10 into close contact with the mold surface 31 of the compressed air mold 30, thereby along the mold surface 31. It shapes and forms the shaping protective film 15. At that time, air between the protective film 10 and the mold surface 31 is discharged out of the mold from the exhaust hole 32 of the compressed air mold 30. Further, the air from the exhaust hole 32 may be sucked by a vacuum suction device and discharged out of the mold.

The heated compressed air blown into the compressed air box 40 preferably has a temperature of 200 to 300 ° C. and a pressure of 8 to 15 MPa (80 to 150 bar, 82 to 153 kg / cm ² ). If the combination of temperature and pressure is deviated, the protective film 10 will not be deformed along the mold surface 31, or the protective resin layer 12 will be cracked or whitened at the bending deformation portion, or at the bending portion. The protective film 10 is too stretched and weakened, or the transparency of the protective resin layer 12 is changed and the aesthetic appearance is easily lost. In the conventional pressure forming (including the case of vacuum pressure forming), the air blown into the pressure box 40 is 0.29 to 0.49 MPa (2.9 to 4.9 bar, 3 to 5 kg / cm ² ). In addition, while the temperature is normal temperature, the pressure of the heated compressed air used in the present invention is considerably high, and the temperature is 200 to 300 ° C. Thus, in the present invention, the protective resin layer 12 is good. Can be shaped.

  The time for blowing the heated compressed air into the compressed air box 40, that is, the heating and pressurizing time for forming the protective film 10 along the mold surface 31 is about 3.0 seconds to 5.0 seconds. Is preferred. When the heating and pressurizing time is too short, the protective film 10 is not easily deformed along the mold surface 31, or the protective resin layer 12 is liable to be cracked or whitened at the bending deformation portion. If the heating and pressurizing time is too long, the protective film 10 is stretched too much at the bent portion and becomes weak, or the transparency or color of the protective resin layer changes and the aesthetic appearance is easily lost. .

  After blowing the heated compressed air for a predetermined time, the blowing is stopped, and the shaping protective film 15 is taken out from the compressed air mold 30 as shown in (2-C) of FIG. Thereafter, trimming (removal of unnecessary portions) of the shaped protective film 15 is performed as necessary.

  In the film insert injection molding step, the base material is injection molded in the same manner as the known film insert injection molding. First, in this process, as shown in FIG. 3 (3-A), the shaping protective film 15 is formed such that the protective resin layer 12 side is one mold surface 52 of the injection mold 50 (usually a movable mold). Place it so that it faces the mold surface. The mold surface 52 is formed according to the shape of the shaping protective film 15. Next, as shown in FIG. 3 (3-B), the injection mold 50 is clamped to inject the base resin 16 into the injection mold 50, and on the side opposite to the protective resin layer 12. A base material 19 is laminated to form the multilayer resin molded product 1 in which the shaping protective film 15 and the base material 19 are integrated. After the injection mold 50 is cooled, the injection mold 50 is opened to remove the multilayer resin molded product 1. Reference numeral 51 denotes a movable mold of the injection mold 50, reference numeral 55 denotes a fixed mold, and reference numeral 56 denotes a gate. The kind of the resin 16 for the base material is not particularly limited as long as it is a resin used for injection molding, and is determined according to the use of the multilayer resin molded product. Examples thereof include polypropylene, polystyrene, acrylonitrile / butadiene / styrene copolymer (ABS), acrylic resin, polycarbonate, polyamide, and polyimide. In particular, a film having good adhesion to the shaped protective film 15 is preferable. Moreover, the thickness of the base material 19 is determined by the use and size of the multilayer resin molded product. The color of the resin 16 for the substrate is appropriately determined, but is preferably light-impermeable from the viewpoint of decoration.

  The multilayer resin molded product 1 thus manufactured has a surface covered with the protective resin layer (hard coat layer) 12 and has high scratch resistance. By making it glossy and transparent, the aesthetics become good. Furthermore, the multilayer resin molded product 1 has a very high aesthetic appearance because the protective resin layer 12 on the surface is not cracked or whitened at the corners or the bent portions between the two surfaces.

  A second embodiment will be described. 4 is a partial cross-sectional view of a protective film according to the second embodiment of the present invention, FIG. 5 is a schematic view of a protective film shaping process according to the second embodiment, and FIG. 6 is a schematic view of a film insert injection molding process according to the second embodiment. It is.

  As shown in FIG. 4, the second embodiment uses a protective film 10 </ b> A in which a surface printing layer 13 is partially formed on the surface of the protective resin layer 12 instead of the protective film 10 of the first embodiment. The others are the same as those in the first embodiment. The surface print layer 13 is made of coloring or matte coloring, and is provided for enhancing decorativeness. The site | part in which the said surface printing layer 13 is provided is suitably determined by a decoration property, a use, etc. The surface printed layer 13 in the illustrated example is provided in a frame shape on the edge of the surface of the multilayer resin molded product 1A as shown in (6-B) of FIG. The surface print layer 13 is formed by a known printing method. Examples of the printing method include gravure printing, flexographic printing, silk screen printing, and the like.

  In addition, the protective film shaping | molding process of 2nd Embodiment heats the said protective film 10A as shown to (5-A) of FIG. 5, Then, as shown to (5-B) of FIG. The film 10A is shaped by placing it on the pressure mold 30 so that the surface printing layer 13 faces the mold surface 31 of the pressure mold 30, and a shaping protective film 15A shown in FIG. Form.

  Further, in the film insert injection molding process of the second embodiment, as shown in FIG. 6 (6 -A), the protective resin layer 12 side is one mold surface 52 of the injection mold 50 (the mold surface of the movable mold 51. 52) is placed on the movable mold 51 of the injection mold 50, and the base material 19 is injection-molded as shown in (6-B) of FIG. A multilayer resin molded product 1A in which the film 15A and the base material 19 are integrated is formed. In the multilayer resin molded product 1A, the protective resin layer 12 is partially covered (hidden) with the surface printed layer 13 and has high decorativeness.

  A third embodiment will be described. FIG. 7 is a partial sectional view of a protective film according to the third embodiment of the present invention, FIG. 8 is a schematic view of a protective film shaping process according to the third embodiment, and FIG. 9 is a schematic view of a film insert injection molding process according to the same embodiment. It is.

  In the third embodiment, as shown in FIG. 7, instead of the protective film 10 of the first embodiment, a protective film 10 </ b> B in which an inner surface printed layer 14 is partially formed on the side surface opposite to the protective resin layer 12. The others are the same as in the first embodiment. The plastic film 11 is made of a transparent material. The inner surface printed layer 14 is made of coloring that can be visually recognized through the transparent protective resin layer 12, and is configured to enhance decorativeness such as characters, figures, patterns, and the like. The position of the inner surface printed layer 14 is appropriately determined depending on decorativeness, usage, and the like. As shown in FIG. 9, the inner surface printed layer 14 in the illustrated example is provided so as to be positioned substantially at the center of the multilayer resin molded product 1B. The inner surface printing layer 14 is formed by a known printing method. Examples of the printing method include gravure printing, flexographic printing, silk screen printing, and the like.

  In addition, the protective film shaping | molding process of 3rd Embodiment heats the protective film 10B as shown to (8-A) of FIG. 8, Then, as shown to (8-B) of FIG. 8, the said protective film 10B is placed and shaped in the compressed air mold 30 so that the protective resin layer 12 side faces the mold surface 31 of the compressed air mold 30 to form a shaped protective film 15B shown in (8-C) of FIG. To do.

  Further, in the film insert injection molding process of the third embodiment, as shown in FIG. 9 (9-A), the protective resin layer 12 side is one mold surface 52 of the injection mold 50 (the mold surface of the movable mold 51). 52) is placed on the movable mold 51 of the injection mold 50, and the base material 19 is injection molded as shown in (9-B) of FIG. A multilayer resin molded product 1B in which the film 15B and the base material 19 are integrated is formed. The multilayer resin molded product 1 </ b> B has a high decorative property because the inner surface printed layer 14 can be seen through the transparent protective resin layer 12.

  A fourth embodiment will be described. FIG. 10 is a partial cross-sectional view of a protective film according to a fourth embodiment of the present invention, and FIG. 11 is a cross-sectional view of a multilayer resin molded product obtained in a film insert injection molding process according to the fourth embodiment.

  In the fourth embodiment, as shown in FIG. 10, a surface printed layer 13 is partially formed on the surface of the protective resin layer 12, and is covered with the surface printed layer 13 on the side surface opposite to the protective resin layer 12. Using the protective film 10C in which the inner surface printed layer 14 is partially formed at a position where it is not (not concealed), the shaped protective film 15C is formed in the same manner as the protective film shaping step of the first to third embodiments. Further, the multilayer resin molded product 1C shown in FIG. 11 is manufactured in the same manner as the film insert injection molding process of the first to third embodiments. The multilayer resin molded product 1 </ b> C exhibits good decorative properties due to the surface printing layer 13, the transparent protective resin layer 12, and the inner surface printing layer 14. In addition, the presence of the protective resin layer 12 exhibits good scratch resistance.

  A fifth embodiment will be described. FIG. 12 is a partial sectional view of a protective film in the fifth embodiment of the present invention, FIG. 13 is a schematic diagram of a protective film shaping process in the fifth embodiment, and FIG. 14 is a schematic diagram of a film insert injection molding process in the same embodiment. It is.

  In the fifth embodiment, as shown in FIG. 12, instead of the protective film 10 of the first embodiment, a protective film 10D having an inner surface printed layer 141 formed on the side surface opposite to the protective resin layer 12 is used. It is. The example shown in the figure is a case where a box-shaped multilayer resin resin molded product 1D having a concave portion at the center and an opening K as shown in FIG. 14 (14-C) is manufactured. In the following embodiments, the same members as those in the first to fourth embodiments are denoted by the same reference numerals. The protective film 10D is made of a transparent plastic film 11 and has an inner surface printed layer 141 composed of a light-transmitting portion 14A and a light-impermeable portion 14B on the surface opposite to the protective resin layer 12. Consists of formed. In the illustrated example, the light transmissive portion 14A is provided in a portion closer to one side with respect to the center of the multilayer resin molded product 1D (a portion closer to the left in the illustrated example), and the other portion is a light impermeable portion. 14B. The light-transmitting portion 14A is made of a light color or the like that is easy to transmit light, such as a light color or a light color, while the light-impermeable portion 14B is made of a color that is difficult to transmit light, such as a dark or dark color. Become. Further, the light-transmitting portion 14A is made of a character, figure, pattern, or the like that enhances decorativeness.

  In the protective film shaping step of the fifth embodiment, after the protective film 10D is heated as shown in FIG. 13 (13-A), as shown in FIG. 13 (13-B), the protective film 10D. Is disposed in the compressed air mold 30D so that the side opposite to the protective resin layer 12, that is, the inner surface printed layer 141 side faces the mold surface 31D of the compressed air mold 30D, and the compressed air box as in the first embodiment. Heated compressed air is blown into 40 and shaped, and unnecessary portions are cut out by trimming to form a shaped protective film 15D shown in FIG. 13 (13-C). In addition, the mold surface 31D of the compressed air mold 30D has an uneven shape corresponding to the shape of the multilayer resin molded product, and in this embodiment, a recess 311 is formed at the center, and the shaping protective film 15D is formed of the mold The bottom surface of the recess formed by the recess 311 of the surface 31D is cut out to form an opening 151.

  In the film insert injection molding process of the fifth embodiment, first, as shown in FIG. 14 (14-A), the protective resin layer 12 side is one mold surface 52D of the injection mold 50D1 (movable mold 51D1). The shaping protective film 15D is disposed on the movable mold 51D1 of the injection mold 50D1 so as to face the mold surface 52D), and then the first base as shown in the left side view of (14-B) of FIG. The material resin 16A is injected into the injection mold 50D1, and a first base material 19A covering the inner surface printed layer 141 is laminated on the surface opposite to the protective resin layer 12. The injection mold 50D1 is a three-plate type known as an injection mold. On the mold surface 52D of the movable mold 51D1, a protrusion 53D is formed at a position corresponding to the opening 151 of the shaping protective film 15D, and when the shaping protective film 15D is disposed on the mold surface 52D. The opening 151 is fitted into the protrusion 53D. The first base resin 16A is made of transparent (colorless transparent or colored transparent), and is made of an appropriate material. For example, acrylonitrile-butadiene-styrene resin (ABS), polyethyl methacrylate resin (PMMA) And polycarbonate resin (PC). In addition, the thickness of the first base resin 16A is preferably 1.0 to 2.5 mm in view of light transmittance and the thickness and weight of the multilayer resin molded product.

  After the molding of the first base material 19A, as shown in the right side view of FIG. 14 (14-B), the shaping protective film is applied to a two-plate type injection molding die 50D2 composed of a fixed die 55D2 and a movable die 51D2. A laminated product of 15D and the first base material 19A is disposed, and for the second base material except for the light-transmitting portion 14A or the light-transmitting portion 14A of the inner surface printed layer 141 and its periphery in the injection mold 50D2. Resin 16B is injected. Then, the second base material 19B is laminated on the first base material 19A without covering the light transmissive portion 14A of the inner surface printed layer 141, and as shown in FIG. 14 (14-C), the first base material 19B is laminated. A base material 19D composed of a base material 19A and the second base material 19B is formed. After the injection mold 50D2 is cooled, the injection mold 50D2 is opened to remove the multilayer resin molded product 1D. The second base material resin 16B (second base material 19B) has an opaque or light-shielding color.

  According to the fifth embodiment, in the multilayer resin molded product 1D, the portion of the first base material 19A that is not covered with the second base material 19B is illuminated with an illumination device, whereby the inner surface printed layer 141 is obtained. The light transmissive portion 14A can be turned on (emitted), and is easily visible from the outside. In addition, since the transparent first base material 19A is laminated on the shaping protective film 15D and reinforced with the backing in the portion not covered with the second base material 19B, it bends when the multilayer resin molded product 1D is used. And can prevent damage. Furthermore, the transparency and color unevenness of the protective resin layer 12 that may occur during injection molding of the base material can be made inconspicuous due to the presence of the transparent first base material 19A.

  A sixth embodiment will be described. FIG. 15 is a partial cross-sectional view of a protective film in the sixth embodiment of the present invention, FIG. 16 is a schematic diagram of a protective film shaping process in the sixth embodiment, and FIG. 17 is a schematic diagram of a film insert injection molding process in the same embodiment. It is.

  In the sixth embodiment, the protective film 10E shown in FIG. 15 is used instead of the protective film 10D of the fifth embodiment, and other configurations are the same as those of the fifth embodiment. In the protective film 10E, the plastic film 11 is made transparent, and a surface printing layer 13 is partially formed on the surface of the protective resin layer 12, and the surface opposite to the protective resin layer 12 is light transmissive. An inner surface printed layer 141 composed of a portion 14A and a light impermeable portion 14B is formed, and the light transmissive portion 14A is at a position not covered (not concealed) by the surface printed layer 13, In the protective film 10D of the fifth embodiment, the surface printing layer 13 is provided on the surface of the protective resin layer 12 so as not to cover the light transmissive portion 14A. In addition, the said surface printing layer 13 is as having demonstrated in the said 2nd Embodiment, For example, let it be a thing of light impermeability and a matte thing. The protective film 10E in the illustrated example has the light transmissive portion on a part of one side (left side in the illustrated example) of the opening K of the multilayer resin molded product 1E, as shown in (17-C) of FIG. 14A is provided, and the other portion is a light-impermeable portion 14B, and the surface printed layer 13 is provided so as to surround the opening K in a frame shape. In the sixth embodiment, the same members as those in the fifth embodiment are denoted by the same reference numerals as those in the fifth embodiment.

  The protective film shaping step and the film insert injection step of the sixth embodiment are performed in the same manner as in the fifth embodiment, but a repetitive description is omitted to avoid duplication. 16 (16-A) to (16-C) show the protective film shaping process in the sixth embodiment, and FIG. 17 (17-A) to (17-C) The film insert injection molding process in 6 embodiment is shown. A reference numeral 15E in FIGS. 16 and 17 indicates a shaped protective film shaped using the protective film 10E.

  According to the sixth embodiment, in the multilayer resin molded product 1E, the portion of the first base material 19A that is not covered with the second base material 19B is illuminated with an illumination device, whereby the inner surface printed layer 141 is obtained. The light transmissive portion 14A can be turned on (illuminated), and is easily visible from the outside. Further, since the surface print layer 13 is provided at a position not covering the light transmissive portion 14A, the surface print layer 13 of the multilayer resin molded product 1E can be formed without hindering the visibility of the light transmissive portion 14A. The decorativeness can be enhanced. Moreover, the portion not covered with the second base material 19B is reinforced by lining the transparent first base material 19A on the shaping protective film 15E, so that the multilayer resin molded product 1E is used. It is possible to suppress bending and breakage. Furthermore, unevenness such as transparency and color of the protective resin layer 12 that may occur during injection molding of the base material 19 can be made inconspicuous due to the presence of the transparent first base material 19A.

  18 and 19, the multilayer resin molded product P for a shift operation unit panel (box) for an automobile shown in FIGS. 18 and 19 is manufactured according to the sixth embodiment using the protective film 10E of the sixth embodiment. An example is shown. The central opening K in the multilayer resin molded product P is a shift lever insertion portion. Further, the light-transmitting portion 14A of the inner surface printed layer 141 is composed of characters, symbols, and the like indicating shift positions and the like, and can be seen through from the outside through the plastic film 11 and the protective resin layer 12. Further, the light transmissive portion 14A and the periphery thereof are illuminated by an illumination device such as a light emitting diode disposed on the back side of the multilayer resin molded product P, whereby the characters and symbols of the light transmissive portion 14A are brightly emitted. (Lights up). The same members and parts as those of the sixth embodiment are denoted by the same reference numerals as those used in the sixth embodiment.

  In this example, the plastic film 11 of the protective film 10E is made of a colorless and transparent (natural) PC, and the thickness is 375 μm, while the protective resin layer 12 is a colorless and transparent PMMA + PU UV hard coat agent and has a thickness of 4 μm ± 25%, comprising a hard coat layer formed by dipping coating. The surface printing layer 13 is made of matte gray formed by silk printing. The inner surface printed layer 141 is formed by silk printing, and the light-transmitting portion 14A is composed of light-transmitting white, orange, green and other characters and symbols, while the light-impermeable portion 14B is light-impermeable. Made of transparent black.

  The heating temperature of the protective film 10E in the protective film shaping step is 110 ± 10 ° C., the heating time is 4.5 to 5.0 seconds, the temperature of the heated compressed air is 300 ° C., and the pressure is 9 MPa ± 10% (90 bar ± 10%). ), Pressurization time is 3 seconds. The transparent first base resin 16A (first base material 19A) in the film insert injection molding step is made of colorless and transparent ABS and has a thickness of 2.0 mm. The second base material resin 16B (second base material 19B) is made of black ABS and has a thickness of 1.5 mm.

  The multilayer resin molded product P obtained in this example had good aesthetics, with no cracks or whitening at the corners or between the two bent portions of the transparent protective resin layer 12. In addition, the transparent protective resin layer 12 has no color unevenness.

  In addition, the manufacturing method of the multilayer resin molded product of the present invention is not limited to the panel for the shift lever operation part of the automobile as described above, the panel of the operation part of the air conditioner, the other operation part panel, the box-shaped case, The present invention can be applied to the manufacture of various products such as a window member that covers the indicator screen.

It is a fragmentary sectional view of the protective film in a 1st embodiment of the present invention. It is the schematic of the protective film shaping process in 1st Embodiment. It is the schematic of the film insert injection molding process in 2nd Embodiment. It is a fragmentary sectional view of the protective film in a 2nd embodiment. It is the schematic of the protective film shaping process in 2nd Embodiment. It is the schematic of the film insert injection molding process in 2nd Embodiment. It is a fragmentary sectional view of the protective film in a 3rd embodiment. It is the schematic of the protective film shaping process in 3rd Embodiment. It is the schematic of the film insert injection molding process in 3rd Embodiment. It is a fragmentary sectional view of the protective film in a 4th embodiment. It is sectional drawing of the multilayer resin molded product manufactured in 4th Embodiment. It is a fragmentary sectional view of the protective film in a 5th embodiment. It is the schematic of the protective film shaping process in 5th Embodiment. It is the schematic of the film insert injection molding process in 5th Embodiment. It is a fragmentary sectional view of the protective film in a 6th embodiment. It is the schematic of the protective film shaping process in 6th Embodiment. It is the schematic of the film insert injection molding process in 6th Embodiment. It is a perspective view of the multilayer resin molded product manufactured by the Example. It is AA sectional drawing of FIG.

Explanation of symbols

10, 10A, 10B, 10C, 10D, 10E Protective film 11 Plastic film 12 Protective resin layer (hard coat layer)
DESCRIPTION OF SYMBOLS 13 Surface printing layer 14,141 Inner surface printing layer 14A The light-transmitting part of the inner surface printing layer 141 14B The light-impermeable part of the inner surface printing layer 141 15,15A, 15B, 15C, 15D, 15E Shaped protective film 16 For base materials Resin 16A First base resin 16B Second base resin 19, 19D Base material 19A First base material 19B Second base material 25 Heating device 30, 30D Pressure mold 40 Pressure box 50, 50D1, 50D2 Injection mold 51 , 51D1,51D2 Movable type 55,55D1,55D2 Fixed type

Claims (6)

A protective film in which a transparent protective resin layer is laminated on one side of a plastic film is heated to 100 to 140 ° C. and placed in a compressed air mold, and 200 to 300 ° C. and 8 to 15 MPa in a compressed air box combined with the compressed air mold. A protective film shaping step of obtaining a shaped protective film shaped into the mold surface shape by blowing heated compressed air and bringing the protective film into close contact with the compressed air mold surface;
The shaping protective film is disposed in the injection mold so that the protective resin layer side faces one mold surface of the injection mold, and the shaping resin is injected into the injection mold to inject the shaping resin. By a film insert injection molding process in which a base material is laminated and formed on the side opposite to the protective resin layer of the protective film,
A method for producing a multilayer resin molded product, comprising obtaining a multilayer resin molded product in which the shaped protective film and the substrate are integrated.   The method for producing a multilayer resin molded product according to claim 1, wherein the protective film has a surface printing layer partially formed on a surface of the protective resin layer.   The method for producing a multilayer resin molded article according to claim 1, wherein the protective film is made of a transparent plastic film, and an inner surface printed layer is formed on a surface opposite to the protective resin layer.   The multilayer resin molded product according to claim 3, wherein a surface printing layer is partially formed on a surface of the protective resin layer, and the inner surface printing layer is not covered with the surface printing layer. Method. The protective film consists of the plastic film made of a transparent material, and an inner surface printing layer made up of a light-transmitting part and a light-impermeable part on the surface opposite to the protective resin layer,
In the film insert injection molding process,
A transparent first base resin is injected into the injection mold in which the shaping protective film is disposed, and the inner printed layer is covered on the surface opposite to the protective resin layer of the shaping protective film. Laminating a first base material,
After the first base material is formed, the inner surface print layer is injected into the injection mold by injecting the resin for the second base material except for the light transmissive portion of the inner surface print layer or the light transmissive portion and its periphery. The base material which consists of a said 1st base material and a said 2nd base material is formed by laminating | stacking a 2nd base material on the said 1st base material, without covering the light transmissive part of Claim 1 characterized by the above-mentioned. The manufacturing method of the multilayer resin molded product of description. In the protective film, the plastic film is transparent, and a surface printing layer is partially formed on the surface of the protective resin layer, and a light transmissive portion and a light non-transmissive are formed on a surface opposite to the protective resin layer. An inner surface printed layer made of a conductive portion is formed, and the light transmissive portion is in a position not covered with the surface printed layer,
In the film insert injection molding process,
A transparent first base resin is injected into the injection mold in which the shaping protective film is disposed, and the inner printed layer is covered on the surface opposite to the protective resin layer of the shaping protective film. Laminating a first base material,
After the first base material is formed, the inner surface print layer is injected into the injection mold by injecting the resin for the second base material except for the light transmissive portion of the inner surface print layer or the light transmissive portion and its periphery. The base material which consists of a said 1st base material and a said 2nd base material is formed by laminating | stacking a 2nd base material on the said 1st base material, without covering the light transmissive part of Claim 1 characterized by the above-mentioned. The manufacturing method of the multilayer resin molded product of description.

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