JP2009000963A - Overlay film for resin molding and its manufacturing process and base material for resin molding and resin molding using overlay film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an overlay film which exhibits a strong adhesive strength between a resin layer composed of an ABS resin and a polycarbonate resin and a polycarbonate film constituting the surface layer and yet retains an enough metallic appearance. <P>SOLUTION: The overlay film (a) is obtained by laminating a polycarbonate film 4 on the surface of an ABS resin film 2 containing a metallic pigment with an acrylic adhesive 3. The base material A for resin moldings is obtained by the overlay film (a) on the surface of a resin layer 1 composed of an ABS-based resin, a polycarbonate resin or a mixture resin thereof. This construction enhances the adhesive strength among the layers and prevents delamination while retaining an enough metallic appearance. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an exterior film used for a resin molded product, a method for producing the same, and a substrate for a resin molded product using the exterior film and a resin molded product. More specifically, the surface of the resin molded product has a metallic appearance. It is related with the improvement of the exterior film for doing.

Today, ABS-based resin molding materials with good moldability are widely used as synthetic resin moldings such as suitcases, electrical appliances, and vehicle interior / exterior moldings.
As described above, some resin molding materials using ABS resin or the like have a decorative finish on the surface by laminating a metallic-like exterior film on the surface of a sheet-like resin layer serving as a base material. .
The metallic finish can enhance the appearance of the product, and is often used for the synthetic resin molded products as described above.

By the way, a resin-molded material having a metallic-like surface decorative finish, in particular, a material mainly composed of an ABS-based resin or a polycarbonate resin, has, for example, a metallic printed layer on the surface of a resin layer made of ABS-based resin. A polycarbonate film printed on the back surface is laminated to form a base material such as a sheet, and the base material is formed into a resin molded product having a desired shape by, for example, press molding with a mold material while heating the base material.
The metallic printing layer formed between the resin layer and the polycarbonate film is, for example, a mixture of aluminum pigment ink or pearl pigment ink and colored ink, and includes aluminum particles and Pearl particles will be mixed. Therefore, in the formulation that can give a sufficient metallic feeling in appearance, the fine particles mixed in this printed layer increase, the interlayer strength becomes weak, and the laminate strength with the resin layer such as ABS does not increase. there were. That is, when an impact force is applied to the resin molded product from the outside, there is a problem that delamination occurs in the printed layer and the polycarbonate film peels off.
In order to prevent such delamination in the printed layer, it is conceivable to reduce the amount of aluminum pigment ink or pearl pigment ink, but in that case, a sufficient metallic feeling cannot be obtained and the design looks good. This causes a problem of disappearing.

  As described above, the present applicant is unaware of the existence of a document relating to a technique of laminating a polycarbonate film on the surface of a resin layer made of ABS resin or polycarbonate resin through a metallic color layer.

  The present invention has been made in view of the above-described conventional circumstances, and the target treatment is a resin layer mainly composed of an ABS-based resin or a polycarbonate resin while maintaining a sufficiently metallic design. It is in providing an exterior film with high adhesive strength.

In order to achieve the above object, an exterior film for a resin molded product according to the present invention is characterized in that a polycarbonate film is laminated on the surface of an ABS resin film containing a metallic pigment via an acrylic adhesive.
The exterior film having such a configuration can be laminated in a close contact state with a desired strength on the surface of a resin layer made of an ABS resin, a polycarbonate resin, or a mixed resin thereof without causing a delamination. That is, the interlayer between the resin layer and the exterior film is in close contact with the ABS resin film and ABS resin made of the same ABS resin, or the polycarbonate resin having good compatibility with the ABS resin film in terms of adhesion strength. Sufficient strength can be secured.

In the present invention, an aluminum pigment, a pearl pigment, a copper pigment or the like can be preferably used as the metallic pigment.
Moreover, it is preferable to laminate | stack an exterior film and the resin layer on the resin layer surface at the time of shaping | molding of a resin layer (at the time of extrusion molding etc.).

  The particle size of the metallic particles contained in the metallic pigment is preferably 10 to 100 μm. The metallic particles are, for example, aluminum particles, pearl particles, copper particles and the like, and the above-described average particle size range is preferable in view of appearance. However, the average particle diameter of the metallic particles may be arbitrarily changed, and an average particle diameter outside the above range may be used.

  It is preferable that metallic particles are contained in the acrylic adhesive. As for the inclusion of the metallic particles, it is preferable to mix an appropriate amount of an aluminum pigment, a pearl pigment, an aluminum pigment ink, or a pearl pigment ink into the acrylic adhesive.

  In the present invention, the metallic pigment is preferably composed of one or more of an aluminum pigment, a pearl pigment, and a copper pigment.

  The exterior film according to the present invention is extremely useful when used as a decorative layer that is laminated on the surface of a resin layer made of an ABS resin, a polycarbonate resin, or a mixed resin thereof and exhibits a metallic appearance.

  The present invention uses a base for a resin molded product obtained by laminating the above exterior film on the surface of a resin layer made of an ABS-based resin, a polycarbonate resin, or a mixed resin thereof, and the base for a resin molded product. It also includes a resin molded product exhibiting a metallic appearance.

The exterior film according to the present invention is formed by pressure-bonding an ABS resin film coated with an acrylic adhesive, after the solvent of the acrylic adhesive is volatilized by a heating means, and again laminated with a polycarbonate film by a heating means. It is preferable to manufacture by the method to do.
As a manufacturing method for realizing such pressure bonding, for example, a laminate molding method or an emboss molding method that satisfies the above conditions can be given.
By adopting such a process, it is possible to eliminate the influence due to the remaining solvent and to obtain a predetermined effect for preventing delamination.

  According to the present invention, the following excellent actions and effects can be expected.

The exterior film for a resin molded article according to the present invention is obtained by laminating a polycarbonate film on an ABS resin film surface containing a metallic pigment via an acrylic adhesive, and by containing a metallic pigment in the ABS resin film, Appearance of high design with a metallic feel can be expressed. Moreover, a high adhesion strength can be ensured by laminating the ABS resin film and the polycarbonate film on the surface layer via an acrylic adhesive. By laminating such an exterior film and a resin layer made of ABS resin, polycarbonate resin, or a mixed resin thereof having good compatibility in terms of adhesion strength, for resin molded products having high adhesion strength between all layers. A base material and a resin molded product can be obtained.
Therefore, it is possible to contribute to the provision of a resin molded product having a high adhesion strength that has a metallic appearance with high designability and does not cause delamination even when an impact force is applied from the outside.

  Further, when the average particle size of the metallic particles contained in the metallic pigment is 10 to 100 μm, more preferably 10 to 60 μm, the reflection obtained by the metallic particles in the ABS resin film is greatly improved, resulting in a metallic appearance. The designability of the resin molded product can be improved more effectively.

  In addition, when metallic particles are included in the acrylic adhesive, the metallic particles are mixed in the acrylic adhesive layer on the ABS resin film surface side, so that the metallic layer is visible from the exterior film surface side through the polycarbonate film. As a result, the metallic texture and appearance can be further improved.

  When one or more of aluminum pigments, pearl pigments and copper pigments are used as metallic pigments, the types and combinations of metallic pigments are the types of resins in resin molded products and products It is possible to arbitrarily select the metallic texture according to the application, size, shape, etc., and to change the metallic texture appropriately, and there is an effect that the design expression range is widened.

  Moreover, the base material for resin molded products and the resin molded product according to the present invention can exhibit the above-described advantages of the exterior film of the present invention as they are.

  In addition, the exterior film according to the present invention is formed by laminating a polycarbonate film between rolls at a predetermined temperature after heating the ABS resin film coated with the acrylic adhesive at a predetermined temperature to volatilize the solvent of the acrylic adhesive. Can be pressure-bonded to the ABS resin film and the polycarbonate film more strongly and reliably through an acrylic adhesive, and the strength and durability as an exterior film can be reduced. It is possible to increase the effects and the like more effectively.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
A shown in FIG. 1 is a sheet-shaped substrate for a resin molded product for molding a resin molded product, and the substrate A is formed by laminating a metallic-like exterior film a on the surface of the resin layer 1. It is made up of.

  The exterior film a is composed of an ABS resin film 2 adhered to the surface of the resin layer 1, an acrylic adhesive layer 3 applied to the surface, and a polycarbonate laminated thereon via the acrylic adhesive layer 3. It is composed of a film 4.

The resin layer 1 may be molded using an ABS resin or a polycarbonate resin, or may be molded using a blend resin of an ABS resin and a polycarbonate resin. In this example, an ABS resin is used as the resin layer 1. Therefore, the ABS resin layer 1 will be described below.
The ABS-based resin layer 1 has a thickness required as the base A for a resin molded product in order to obtain a desired resin molded product (product), for example, a sheet shape of about 1 mm to 1.5 mm, or 1.5 mm to Extruded to form a plate of about 5 mm, and at the same time as the extrusion, the exterior film a is integrally laminated on the surface of the ABS resin layer 1 to form a base A for a sheet-shaped resin molded product. Get.

  The resin molded product substrate A thus configured can be used for molding various resin molded products because of its good moldability. However, the resin layer 1 has a thickness corresponding to the resin molded product intended for molding. The thickness may be set arbitrarily.

  As described above, the exterior film a is formed by laminating the ABS resin film 2 serving as a metallic layer (metallic pigment-containing layer) and the polycarbonate film 4 serving as a surface layer via an acrylic adhesive layer 3. In the case of this example, after an acrylic adhesive is applied to one of the ABS resin film 2 and the polycarbonate film 4 of the surface layer (usually ABS resin film 2), it is integrally bonded by thermocompression bonding using an embossing laminator. Both are laminated.

  The ABS resin film 2 in the exterior film a is a layer seen through from the outside (surface side) through the polycarbonate film 4 and the acrylic adhesive layer 3, and contains a metallic pigment so as to exhibit a metallic appearance. Then, it is formed into a film shape.

As the metallic pigment, an aluminum pigment, a pearl pigment, a copper pigment, or the like is used. The aluminum particles, pearl particles, and copper particles contained in these pigments may have any particle size, but if they have an average particle size in the range of 10 to 60 μm, more metallic reflection will occur. It can be expressed vividly.
In addition, any one of the various pigments described above may be used, or two or more may be mixed and used. In the case of this example, an aluminum pigment and a pearl pigment are mixed and kneaded into the ABS resin film 2, thereby a sufficient metallic feeling can be expressed. When the kneading ratio of the aluminum pigment and the pearl pigment is set to 30% by weight or less, preferably 10% by weight or less with respect to the ABS resin, it becomes possible to maintain a high adhesion strength while providing a sufficient metallic feeling.

When the exterior film a is actually laminated, it is molded using a pressure roll apparatus R as shown in FIG.
When the film is laminated by the pressure roll apparatus R, the ABS resin film 2 coated with an acrylic adhesive on the surface is passed through the induction roll 10a heated to 90 ° C. to 100 ° C., and the coated acrylic is applied. Volatilizes the solvent content of the adhesive. At the same time, the polycarbonate film 4 is heated by passing it through a guide roll 10b heated to 40 to 50 ° C. Then, both the films 2 and 4 are introduced in the form wound around the outer periphery of the large-diameter drum 11 along the guiding rolls 10a and 10b.

That is, the preheated ABS resin film 2 and the polycarbonate film 4 pass in a state where the outer circumferences of the relatively large-diameter drums 11 heated to 160 ° C. are overlapped, and thus preliminarily laminated while being heated. The
Next, the two films 2 and 4 are passed through the peeling roll 12 heated to 130 ° C. and the roll 13 heated to 120 ° C. in a folded manner, and then strongly passed between the embossing roll 14 and the rubber roll 15. Crimping is applied to both films 2 and 4 which are integrated at the same time. Particularly good results can be obtained when the pressure when the films 2 and 4 are pressed is set to 2.5 MPa.
In this example, both the laminated films 2 and 4 are crimped by embossing roll 14 and rubber roll 15 and subjected to embossing, but both laminated films 2 and 4 are between rolls whose outer surfaces are mirror-finished. You may press-fit and mirror finish.

(Example)
Hereinafter, the present invention will be described using more specific examples.
Specific examples of samples that can be used in this example are as follows, for example.

[Polycarbonate film]
As the polycarbonate resin film, a pantolite film manufactured by Teijin Kasei Co., Ltd. or an Iupilon film manufactured by Mitsubishi Engineering Plastics Co., Ltd. can be used.

[ABS resin film]
The ABS resin film (thickness: 0.2 to 0.3 mm) is a general ABS made by Japan A & L Co., Ltd., Clarastic K-2540A, S3717L, K-1163, Santac ET-70, Toray Co., Ltd. Blendex 201 manufactured by UMGABS, Techno ABS 150, 170 manufactured by Technopolymer, and the like can be used.

  As the transparent ABS, Clarastic ST600 manufactured by Japan A & L, Toyolac 930 manufactured by Toray Industries, Inc., and the like can be used.

  As heat-resistant ABS, Techno ABS500 series manufactured by Technopolymer, KU600 series manufactured by Japan A & L, Toyolac 400 series manufactured by Toray Industries, Inc. can be used.

As an alloy ABS, a mixed system of polycarbonate and ABS (polymer alloy), for example, Techneace T-105P manufactured by Japan A & L, Exelloy CK-10, CK-20 manufactured by Technopolymer, Toyolac PX-10 manufactured by Toray Etc. can be used.
Further, a mixed system of nylon and ABS (polymer alloy), for example, Toyolac SX01 manufactured by Toray Industries, Inc. can be used.

The selective blending example and adjustment range of the ABS resin film used in the present invention are shown below.
(Formulation example)
ABS resin (general ABS, transparent ABS, heat-resistant ABS, flame-retardant ABS, alloy (copolymerization) ABS, etc.): 100 parts by weight Metallic pigment, pearl pigment: 1-20 parts by weight Other pigments: 0-20 parts by weight Parts / Modifiers (MBS, Polyca, Nylon, EVA, PVC resin, etc.): 10 to 50 parts by weight Processing aids (Maybrene P series manufactured by Mitsubishi Rayon Co., Kaneka PA series manufactured by Kaneka, equivalent and similar products) Etc.): 0 to 10 parts by weight. Stabilizer, lubricant, other (metal soap, ester lubricant, HALS, UVA, antioxidant, silica, etc.): 1 to 5 parts by weight

  Table 1 shows a blending example of the ABS resin film that was particularly good.

〔adhesive〕
As the adhesive (coating amount: 3 to 5 μm / dry), solvent-type thermoplastic acrylic resin as an acrylic adhesive: Dianal LR-269 manufactured by Mitsubishi Rayon Co., Ltd. was used.

  As a comparative example of the adhesive, a gravure ink medium for solvent-type vinyl chloride as a vinyl vinegar / biacrylic system: SX (NT) -257 medium manufactured by Showa Ink Industries, Ltd. was used. Further, gravure ink medium for solvent-type vinyl chloride as an acrylic urethane adhesive: SX (NT) -200 medium manufactured by Showa Ink Industries, Ltd. was used.

〔Evaluation test〕
The base material for a resin molded product according to the present invention configured by appropriately selecting the various materials described above was able to ensure sufficient adhesion strength between all the layers. The evaluation method and results of the adhesion strength test are shown below. In addition, the adhesive used for the said test used the said chlorinated vinyl acryl-type adhesive agent and the acrylic urethane type adhesive agent as a comparative example other than an acrylic adhesive. The results are also shown.

[Test materials]
As the ABS resin film, a film prepared with the composition shown in Table 1 was used.
As the acrylic adhesive, the aforementioned Dianal LR-269 was used.
The Iupilon film FEB described above was used as the polycarbonate film.

Using these materials, a laminate of an exterior film in which the solvent was removed was used as a sample by a press machine. The laminating time was 3 minutes, and the pressure was 5 MPa. The sample size was 25 mm wide, and the pulling speed was 200 mm / min.
The evaluation method measured the peel strength in a 180 degree peeling test. The results are shown in Table 2.

  Furthermore, using this exterior film, a resin molded product in which a decorative layer is laminated on the surface of a resin layer made of ABS resin, polycarbonate resin, or a mixed resin thereof is molded. The result was obtained.

  By the way, although the base material A for a resin molded product described above expresses an external metallic feeling by containing a metallic pigment in the ABS resin film 2 of the exterior film a, in the present invention, the ABS resin film Metallic particles may be contained in the acrylic adhesive layer 3 for laminating 2 and the polycarbonate film 4. Hereinafter, this case will be described in detail.

  When the acrylic adhesive contains metallic particles, the acrylic adhesive layer 3 can also contain an appropriate amount of aluminum pigment, pearl pigment, aluminum pigment ink, or pearl pigment ink. A metallic feeling can be given. Here, in consideration of dispersibility during inclusion (kneading), it is preferable to use an aluminum pigment ink or a pearl pigment ink. Moreover, it is difficult to mix these pigment inks in a large amount in order to maintain the adhesion strength, and the blending amount is preferably set to 10 parts by weight or less.

  In this case, the base A for a resin molded product is in a state in which metallic particles are also mixed in the adhesive layer 3 formed on the surface side of the ABS resin film 2 kneaded with the metallic pigment, and from the surface through the polycarbonate film 4. Depth is generated in the metallic layer to be seen, and the metallic texture can be further enhanced.

  The metallic pigment ink used in this case is the same as that used for the printing layer in the conventional substrate for resin molded products, but an example of the composition is shown below.

(Example of composition of metallic pigment ink)
Resin: PVC resin, acrylic resin, or mixed resin Pigment: Aluminum, pearl, organic, etc. Solvent: MEK, MIBK, butyl acetate, ethyl acetate, etc. Diluent solvent: MEK, MIBK, ethyl acetate, etc.

As the metallic pigment ink, a vinyl chloride resin, an acrylic resin, or a mixed resin thereof is usually used, a pigment is mixed in a vehicle, and the viscosity is adjusted with a solvent.
In addition, aluminum pigment ink, pearl pigment ink, and colored pigment ink are mixed and adjusted to the desired color tone.

  Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments and specific examples, and various modifications can be made within the scope of the technical idea described in the claims. Needless to say.

The expanded longitudinal cross-sectional view which shows an example of the base material for resin molded products of this invention. The front view which shows the state which laminates a PC film and an ABS film using a pressure roll apparatus.

Explanation of symbols

A: Substrate for resin molded product a: Exterior film 1: Resin layer (ABS resin layer)
2: ABS resin film 3: Acrylic adhesive layer 4: Polycarbonate film R: Pressure roll device

Claims (8)

  An exterior film for a resin molded product, comprising a polycarbonate film laminated on the surface of an ABS resin film containing a metallic pigment via an acrylic adhesive.   The exterior film for a resin molded product according to claim 1, wherein a particle size of the metallic particles contained in the metallic pigment is 10 to 100 µm.   The exterior film for a resin molded product according to claim 1 or 2, wherein the acrylic adhesive contains metallic particles.   The exterior film for a resin molded product according to any one of claims 1 to 3, wherein the metallic pigment is composed of one or more of an aluminum pigment, a pearl pigment, and a copper pigment.   The exterior film for a resin molded product according to any one of claims 1 to 4, wherein the exterior film for a resin molded product is used as a decorative layer that is laminated on a surface of a resin layer made of an ABS-based resin, a polycarbonate resin, or a mixed resin thereof and exhibits a metallic appearance.   A base material for a resin molded article obtained by laminating the exterior film according to any one of claims 1 to 5 on a surface of a resin layer made of an ABS resin, a polycarbonate resin, or a mixed resin thereof.   A resin molded product having a metallic appearance using the substrate for a resin molded product according to claim 6. A method for producing an exterior film for a resin molded product according to any one of claims 1 to 5,
A resin molded article characterized in that an ABS resin film coated with an acrylic adhesive is volatilized by heating and then the solvent content of the acrylic adhesive is volatilized and then laminated with a polycarbonate film between heating rolls. For producing an exterior film for a vehicle.

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