JP2009226615A - Manufacturing method of resin molding having surface functional layer and its molding - Google Patents
Manufacturing method of resin molding having surface functional layer and its molding Download PDFInfo
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- JP2009226615A JP2009226615A JP2008071416A JP2008071416A JP2009226615A JP 2009226615 A JP2009226615 A JP 2009226615A JP 2008071416 A JP2008071416 A JP 2008071416A JP 2008071416 A JP2008071416 A JP 2008071416A JP 2009226615 A JP2009226615 A JP 2009226615A
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- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 6
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- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 3
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- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- XKZQKPRCPNGNFR-UHFFFAOYSA-N 2-(3-hydroxyphenyl)phenol Chemical compound OC1=CC=CC(C=2C(=CC=CC=2)O)=C1 XKZQKPRCPNGNFR-UHFFFAOYSA-N 0.000 description 1
- UMPGNGRIGSEMTC-UHFFFAOYSA-N 4-[1-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexyl]phenol Chemical compound C1C(C)CC(C)(C)CC1(C=1C=CC(O)=CC=1)C1=CC=C(O)C=C1 UMPGNGRIGSEMTC-UHFFFAOYSA-N 0.000 description 1
- NUDSREQIJYWLRA-UHFFFAOYSA-N 4-[9-(4-hydroxy-3-methylphenyl)fluoren-9-yl]-2-methylphenol Chemical compound C1=C(O)C(C)=CC(C2(C3=CC=CC=C3C3=CC=CC=C32)C=2C=C(C)C(O)=CC=2)=C1 NUDSREQIJYWLRA-UHFFFAOYSA-N 0.000 description 1
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- 125000004122 cyclic group Chemical group 0.000 description 1
- MIHINWMALJZIBX-UHFFFAOYSA-N cyclohexa-2,4-dien-1-ol Chemical compound OC1CC=CC=C1 MIHINWMALJZIBX-UHFFFAOYSA-N 0.000 description 1
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- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
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- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920013716 polyethylene resin Polymers 0.000 description 1
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- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
本発明は、表面に機能層を有する樹脂成形体に関する。詳しくは、本発明は、表面に機能層を有する樹脂成形体であって、寸法精度、および生産性に優れた樹脂成形体の製造方法並びにかかる樹脂成形体に関する。 The present invention relates to a resin molded body having a functional layer on the surface. Specifically, the present invention relates to a resin molded body having a functional layer on the surface, and relates to a method for producing a resin molded body excellent in dimensional accuracy and productivity, and the resin molded body.
ガラス板を芳香族ポリカーボネート樹脂に代表される熱可塑性樹脂製の板に代替する試みは従来から幅広い分野で実施されている。その目的は、軽量化、安全性の向上、およびガラスでは不可能な態様での利用などを達成することにある。この中でガラスでは不可能な態様での利用の具体例としては、開口部や偏肉、ボス、リブ形状を有する成形体等が挙げられ、それらの成形体を後加工でなく直接に製造することが開示されている(特許文献1)。また、ガラス板が利用されていた分野では、樹脂板にも耐擦傷性が求められる場合が多く、ハードコートが必須である。ハードコートを樹脂板に施す方法としてはスプレーコート法、フローコート法、ディップコート法を使用する方法が開示されている(非特許文献1)。しかしながら開口部等の複雑な形状の成形体では垂れなどの外観不良が出るという問題がある。一方、射出成形中に箔転写することにより成形体の表面に機能層を施す方法も開示されている(特許文献2)。しかしながら、成形体が大型化、厚肉化、複雑形状化すると熱や樹脂流動の複雑化により転写フィルムが熱劣化して成形体に融着したり、樹脂の流動会合部を有する樹脂成形体ではフィルムが引き伸ばされて皺を生じるという問題がある。 Attempts to replace the glass plate with a plate made of a thermoplastic resin typified by an aromatic polycarbonate resin have been performed in a wide range of fields. Its purpose is to achieve weight reduction, improved safety, and utilization in a manner that is not possible with glass. Among these, specific examples of use in a mode impossible with glass include molded bodies having openings, uneven thickness, bosses, rib shapes, etc., and these molded bodies are directly manufactured rather than post-processed. (Patent Document 1). In fields where glass plates have been used, resin plates are often required to have scratch resistance, and a hard coat is essential. As a method for applying a hard coat to a resin plate, a method using a spray coating method, a flow coating method, or a dip coating method is disclosed (Non-Patent Document 1). However, there is a problem that a molded article having a complicated shape such as an opening has poor appearance such as sagging. On the other hand, a method of applying a functional layer to the surface of a molded body by transferring a foil during injection molding is also disclosed (Patent Document 2). However, if the molded body becomes larger, thicker, or has a complicated shape, the transfer film is thermally deteriorated due to the complexity of heat and resin flow, and is fused to the molded body. There is a problem that the film is stretched to cause wrinkles.
本発明の目的は、上記問題に鑑みてなされたものであり、ハードコートを有する樹脂成形体の射出成形による製造を可能とすることにある。 An object of the present invention is made in view of the above problem, and is to enable production of a resin molded body having a hard coat by injection molding.
本発明者らは、鋭意検討を重ねた結果、キャリアフィルムの特性を最適化し、射出圧縮成形方法との組合せによりフィルムが成形体に融着することなく、皺が無い成形体を得る方法を見出し、本発明を完成するに至った。 As a result of intensive investigations, the present inventors have found out a method for optimizing the characteristics of a carrier film and obtaining a molded body free from wrinkles without the film being fused to the molded body in combination with an injection compression molding method. The present invention has been completed.
本発明によれば、上記課題を解決する手段として、射出圧縮成形法にて、厚みが0.1mm〜2mmであり、融点が220℃以上である表面に機能層を有するフィルムを一方の金型と他方の金型との間に配置し、該金型を型締めして成形キャビティを形成した後、該キャビティ内に熱可塑性樹脂を射出する工程および成形体よりフィルムを剥がす工程を含む射出成形により成形することを特徴とする樹脂成形体の製造方法が提供される。なお、本発明でいうところの成形キャビティとは、可動側金型と固定側金型との型締めにより形成した成形用空間のことを指す。以下、本発明の詳細について説明する。 According to the present invention, as a means for solving the above-mentioned problem, a film having a functional layer on the surface having a thickness of 0.1 mm to 2 mm and a melting point of 220 ° C. or higher is formed by one injection mold by an injection compression molding method. Injection molding including a step of disposing a film from the molded body and a step of injecting a thermoplastic resin into the cavity after the mold is clamped to form a molding cavity. A method for producing a resin molded body characterized by molding is provided. In the present invention, the molding cavity refers to a molding space formed by clamping a movable mold and a fixed mold. Details of the present invention will be described below.
<表面に機能層を有するフィルム>
本発明で使用される表面に機能層を有するフィルムとは、熱可塑性樹脂等からなるキャリアフィルムの表面に機能層を積層したフィルムであり、機能層の代表的なものとしては耐擦傷性を有するハードコート層、図柄等が形成された印刷層などがある。また、キャリアフィルムの材質としてはポリプロピレン系樹脂、ポリエチレン系樹脂、ポリアミド系樹脂、ポリイミド系樹脂、ポリエステル系樹脂、アクリル系樹脂、ポリ塩化ビニル系樹脂、ポリカーボネート系樹脂等が挙げられ、その中でもポリエステル系樹脂、特にポリエチレンナフタレート樹脂が好ましい。
<Film with functional layer on the surface>
The film having a functional layer on the surface used in the present invention is a film obtained by laminating a functional layer on the surface of a carrier film made of a thermoplastic resin or the like, and a typical functional layer has scratch resistance. There are a hard coat layer, a printed layer on which a pattern and the like are formed. Examples of the material for the carrier film include polypropylene resin, polyethylene resin, polyamide resin, polyimide resin, polyester resin, acrylic resin, polyvinyl chloride resin, polycarbonate resin, and the like. Resins, particularly polyethylene naphthalate resins are preferred.
上記フィルムの厚みは0.1mm〜2mmであり、0.1mm〜0.4mmが好ましく、0.2mm〜0.4mmがより好ましい。フィルムの厚みが0.1mmより薄い場合、腰が足りず成形時に皺になり、2mmより厚い場合は形状追随性が損なわれる。 The thickness of the film is 0.1 mm to 2 mm, preferably 0.1 mm to 0.4 mm, and more preferably 0.2 mm to 0.4 mm. When the thickness of the film is less than 0.1 mm, the waist is not sufficient, and when forming, it becomes wrinkle at the time of molding.
上記フィルムの融点は220℃以上であり、250℃以上が好ましく、260℃以上がより好ましい。フィルムの融点が220℃より低い場合、射出成形時に溶融樹脂の熱によってフィルムが成形体に融着する。なお、フィルムの融点の上限は特に限定されないが、550℃以下が好ましい。 The melting point of the film is 220 ° C. or higher, preferably 250 ° C. or higher, and more preferably 260 ° C. or higher. When the melting point of the film is lower than 220 ° C., the film is fused to the molded body by the heat of the molten resin at the time of injection molding. In addition, although the upper limit of melting | fusing point of a film is not specifically limited, 550 degrees C or less is preferable.
<熱可塑性樹脂>
本発明の樹脂成形体を構成する熱可塑性樹脂は、各種の重合体または共重合体、およびこれらに各種の添加剤を配合した樹脂組成物を含む。
熱可塑性樹脂としては、ポリスチレン樹脂、ABS樹脂、AES樹脂、AS樹脂、メタクリル樹脂、ポリカーボネート樹脂、環状ポリオレフィン樹脂、変性PPE樹脂、ポリスルホン樹脂、ポリエーテルスルホン樹脂、ポリアリレート樹脂、およびポリエーテルイミド樹脂などが例示される。これらの中でもポリカーボネート樹脂が最も好ましい。
<Thermoplastic resin>
The thermoplastic resin constituting the resin molded body of the present invention includes various polymers or copolymers, and resin compositions in which various additives are blended.
Examples of the thermoplastic resin include polystyrene resin, ABS resin, AES resin, AS resin, methacrylic resin, polycarbonate resin, cyclic polyolefin resin, modified PPE resin, polysulfone resin, polyethersulfone resin, polyarylate resin, and polyetherimide resin. Is exemplified. Of these, polycarbonate resins are most preferred.
かかるポリカーボネート樹脂は、通常使用されるビスフェノールA型ポリカーボネート以外にも、他の二価フェノールを用いて重合された、高耐熱性または低吸水率の各種のポリカーボネート樹脂であってもよい。ポリカーボネート樹脂はいかなる製造方法によって製造されたものでもよく、界面重縮合の場合は通常一価フェノール類の末端停止剤が使用される。ポリカーボネート樹脂はまた3官能フェノール類を重合させた分岐ポリカーボネート樹脂であってもよく、更に脂肪族ジカルボン酸や芳香族ジカルボン酸、または二価の脂肪族または脂環族アルコールを共重合させた共重合ポリカーボネートであってもよい。ポリカーボネート樹脂の粘度平均分子量は、好ましくは1.3×104〜4.0×104、より好ましくは1.5×104〜3.0×104、更に好ましくは2.0×104〜2.8×104である。芳香族ポリカーボネート樹脂の粘度平均分子量(M)は塩化メチレン100mlにポリカーボネート樹脂0.7gを溶解した溶液から20℃で求めた比粘度(ηsp)を次式に挿入して求めたものである。
ηsp/c=[η]+0.45×[η]2c(但し[η]は極限粘度)
[η]=1.23×10−4M0.83
c=0.7
Such a polycarbonate resin may be various polycarbonate resins having a high heat resistance or a low water absorption, which are polymerized using other dihydric phenols, in addition to the commonly used bisphenol A type polycarbonate. The polycarbonate resin may be produced by any production method, and in the case of interfacial polycondensation, a terminal stopper of a monohydric phenol is usually used. The polycarbonate resin may also be a branched polycarbonate resin obtained by polymerizing trifunctional phenols, and further a copolymer obtained by copolymerizing an aliphatic dicarboxylic acid, an aromatic dicarboxylic acid, or a divalent aliphatic or alicyclic alcohol. Polycarbonate may be used. The viscosity average molecular weight of the polycarbonate resin is preferably 1.3 × 10 4 to 4.0 × 10 4 , more preferably 1.5 × 10 4 to 3.0 × 10 4 , and even more preferably 2.0 × 10 4. ˜2.8 × 10 4 . The viscosity average molecular weight (M) of the aromatic polycarbonate resin is obtained by inserting the specific viscosity (ηsp) obtained at 20 ° C. from a solution of 0.7 g of the polycarbonate resin in 100 ml of methylene chloride into the following equation.
ηsp / c = [η] + 0.45 × [η] 2 c (where [η] is the intrinsic viscosity)
[Η] = 1.23 × 10 −4 M 0.83
c = 0.7
他の二価フェノールを用いて重合された、高耐熱性または低吸水率の各種のポリカーボネート樹脂の具体例としては、下記のものが好適に例示される。
(1)該ポリカーボネートを構成する二価フェノール成分100モル%中、4,4’−(m−フェニレンジイソプロピリデン)ジフェノール(以下“BPM”と略称)成分が20〜80モル%(より好適には40〜75モル%、さらに好適には45〜65モル%)であり、かつ9,9−ビス(4−ヒドロキシ−3−メチルフェニル)フルオレン(以下“BCF”と略称)成分が20〜80モル%(より好適には25〜60モル%、さらに好適には35〜55モル%)である共重合ポリカーボネート。
(2)該ポリカーボネートを構成する二価フェノール成分100モル%中、ビスフェノールA成分が10〜95モル%(より好適には50〜90モル%、さらに好適には60〜85モル%)であり、かつBCF成分が5〜90モル%(より好適には10〜50モル%、さらに好適には15〜40モル%)である共重合ポリカーボネート。
(3)該ポリカーボネートを構成する二価フェノール成分100モル%中、BPM成分が20〜80モル%(より好適には40〜75モル%、さらに好適には45〜65モル%)であり、かつ1,1−ビス(4−ヒドロキシフェニル)−3,3,5−トリメチルシクロヘキサン成分が20〜80モル%(より好適には25〜60モル%、さらに好適には35〜55モル%)である共重合ポリカーボネート。
As specific examples of various polycarbonate resins polymerized using other dihydric phenols and having high heat resistance or low water absorption, the following can be suitably exemplified.
(1) In 100 mol% of the dihydric phenol component constituting the polycarbonate, 4,4 '-(m-phenylenediisopropylidene) diphenol (hereinafter abbreviated as "BPM") component is 20 to 80 mol% (more preferable) 40 to 75 mol%, more preferably 45 to 65 mol%), and 9,9-bis (4-hydroxy-3-methylphenyl) fluorene (hereinafter abbreviated as "BCF") component is 20 to 20 mol. Copolycarbonate which is 80 mol% (more preferably 25 to 60 mol%, more preferably 35 to 55 mol%).
(2) In 100 mol% of the dihydric phenol component constituting the polycarbonate, the bisphenol A component is 10 to 95 mol% (more preferably 50 to 90 mol%, more preferably 60 to 85 mol%), And a BCF component in an amount of 5 to 90 mol% (more preferably 10 to 50 mol%, and still more preferably 15 to 40 mol%).
(3) In 100 mol% of the dihydric phenol component constituting the polycarbonate, the BPM component is 20 to 80 mol% (more preferably 40 to 75 mol%, more preferably 45 to 65 mol%), and The 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane component is 20 to 80 mol% (more preferably 25 to 60 mol%, more preferably 35 to 55 mol%). Copolycarbonate.
これらの特殊なポリカーボネートは、単独で用いてもよく、2種以上を適宜混合して使用してもよい。また、これらを汎用されているビスフェノールA型のポリカーボネートと混合して使用することもできる。 These special polycarbonates may be used alone or in combination of two or more. Moreover, these can also be mixed and used for the bisphenol A type polycarbonate generally used.
これらの特殊なポリカーボネートの製法及び特性については、例えば、特開平6−172508号公報、特開平8−27370号公報、特開2001−55435号公報及び特開2002−117580号公報等に詳しく記載されている。 The production method and characteristics of these special polycarbonates are described in detail in, for example, JP-A-6-172508, JP-A-8-27370, JP-A-2001-55435, and JP-A-2002-117580. ing.
上記の熱可塑性樹脂は、透明性を損なわない範囲において、従来公知の各種の添加剤を含有することができる。かかる添加剤としては、例えば、熱安定剤、酸化防止剤、紫外線吸収剤、光安定剤、着色剤、離型剤、摺動剤、赤外線吸収剤、光拡散剤、蛍光増白剤、帯電防止剤、難燃剤、難燃助剤、可塑剤、強化充填材、衝撃改質剤、光触媒系防汚剤、およびフォトクロミック剤等が例示される。尚、熱安定剤、酸化防止剤、紫外線吸収剤、光安定剤、着色剤、および離型剤などは、従来上記の熱可塑性樹脂における公知の適正量を配合できる。かかる量が樹脂の透明性を阻害することが稀であるからである。 Said thermoplastic resin can contain conventionally well-known various additives in the range which does not impair transparency. Examples of such additives include heat stabilizers, antioxidants, ultraviolet absorbers, light stabilizers, colorants, mold release agents, sliding agents, infrared absorbers, light diffusing agents, fluorescent whitening agents, and antistatic agents. Examples include agents, flame retardants, flame retardant aids, plasticizers, reinforcing fillers, impact modifiers, photocatalytic antifouling agents, and photochromic agents. The heat stabilizer, the antioxidant, the ultraviolet absorber, the light stabilizer, the colorant, the release agent, and the like can be blended with known appropriate amounts in the above thermoplastic resins. This is because such an amount rarely inhibits the transparency of the resin.
また樹脂材料は、通常必要な添加剤を原料樹脂と溶融混練したペレットの形状で、射出成形機に供給される。かかる供給時は水分含有量が十分に低減されることが必要である。ポリカーボネート樹脂の如き水分吸収性の高い熱可塑性樹脂は、十分に乾燥され射出成形機に供給されることが必要である。溶融混練は、従来公知の溶融混練機が利用でき、特にベント式二軸押出機が好適である。また押出中に生じた異物を除去するためのスクリーンを押出機ダイス部前のゾーンに設置することが好ましい。ペレット化に際して外部の埃などの影響を低減する必要がある場合には、押出機周囲の雰囲気を清浄化することが好ましい。更にペレットの製造場所から、射出成形機への製造場所への運搬には、従来光情報記録媒体の基板製造用ペレットに利用される、各種の防塵コンテナが利用できる。 The resin material is usually supplied to an injection molding machine in the form of pellets obtained by melt-kneading necessary additives with a raw material resin. At the time of such supply, the water content needs to be sufficiently reduced. A thermoplastic resin having a high moisture absorption such as a polycarbonate resin needs to be sufficiently dried and supplied to an injection molding machine. For melt kneading, a conventionally known melt kneader can be used, and a vent type twin screw extruder is particularly suitable. Moreover, it is preferable to install a screen for removing foreign substances generated during extrusion in the zone in front of the extruder die. When it is necessary to reduce the influence of external dust during pelletization, it is preferable to clean the atmosphere around the extruder. Furthermore, various dustproof containers that have been conventionally used for pellets for manufacturing substrates of optical information recording media can be used for transportation from the pellet manufacturing location to the manufacturing location for the injection molding machine.
<樹脂成形体>
本発明の製造方法で製造される樹脂成形体の厚みは3mm〜30mmの範囲が好ましく、5〜30mmがより好ましく、8〜30mmが最も好ましい。厚みが3mmより薄い場合、射出成形時に樹脂の剪断によってフィルムが変形してしまう。また、厚みが30mmより厚い場合、射出成形時のフィルムへの熱負荷が大きくなりフィルムが融着する可能性が高くなる。
<Resin molding>
The thickness of the resin molded body produced by the production method of the present invention is preferably in the range of 3 mm to 30 mm, more preferably 5 to 30 mm, and most preferably 8 to 30 mm. When the thickness is less than 3 mm, the film is deformed by the shearing of the resin during injection molding. On the other hand, if the thickness is greater than 30 mm, the thermal load on the film during injection molding increases, and the possibility that the film will be fused increases.
上記樹脂成形体は樹脂の流動会合部を有する樹脂成形体であることが好ましく、開口部を有する樹脂成形体がより好ましい。開口部を有する樹脂成形体の場合、該開口の大きさが500mm2以上が好ましく、3,000mm2以上がより好ましく、30,000mm2以上が最も好ましい。開口部の大きさが500mm2より小さい場合はフィルムがシワになりにくく従来の技術でも成形可能である。なお、500mm2以上の開口部とは、機能層を有する面の開口部の面積が500mm2以上であることを指す。 The resin molded body is preferably a resin molded body having a resin flow association part, and more preferably a resin molded body having an opening. When the resin molded body having an opening, is preferably 500 mm 2 or more the size of the opening, more preferably 3,000 mm 2 or more, 30,000 mm 2 or more is most preferred. When the size of the opening is smaller than 500 mm 2, the film is less likely to be wrinkled and can be formed by conventional techniques. Note that the 500 mm 2 or more openings, refers to the area of the opening portion of the surface having the functional layer is 500 mm 2 or more.
<樹脂成形体の製造方法>
本発明の製造方法は以下の工程を含む製造方法である。
<Production method of resin molding>
The manufacturing method of the present invention is a manufacturing method including the following steps.
(表面に機能層を有するフィルムを一方の金型と他方の金型との間に配置し、該金型を型締めして成形キャビティを形成した後、該キャビティ内に熱可塑性樹脂を射出する工程)
本発明において溶融樹脂は、表面に機能層を有するフィルムを一方の金型と他方の金型との間に配置した後に予め圧縮ストローク分だけ余分に開いた金型キャビティ内に射出充填される。フィルムの配置方法としては金型の上方或いは下方に配置されたフィルムロールを他方に巻き取り送る方法や、枚葉にカットされたフィルムをロボットアームなどにより金型内に配置する方法などがある。また、この際に金型内で真空熱成形により予備賦形を行ってもよい。
(A film having a functional layer on the surface is placed between one mold and the other mold, the mold is clamped to form a molding cavity, and then a thermoplastic resin is injected into the cavity. Process)
In the present invention, the molten resin is injected and filled into a mold cavity that is opened in advance by an amount corresponding to the compression stroke after a film having a functional layer on the surface is disposed between one mold and the other mold. As a method for arranging the film, there are a method in which a film roll arranged above or below the mold is wound up to the other, a method in which a film cut into a sheet is arranged in the mold by a robot arm or the like. At this time, preliminary shaping may be performed by vacuum thermoforming in a mold.
圧縮ストロークと樹脂板の厚みとの合計量は、目的とする樹脂板の厚みに対して、好ましくは1.01〜3倍の範囲、より好ましくは1.05〜2倍の範囲、更に好ましくは1.1〜1.8倍の範囲である。かかる圧縮ストロークの適正値は、成形体の厚みや使用される樹脂の溶融粘度により異なる。例えば樹脂板の厚みが10mm以上、好ましくは12mm以上の場合には、圧縮ストロークの絶対値は、好ましくは0.2〜3mmの範囲、より好ましくは0.3〜2mmの範囲である。成形体の厚みが少ない場合には、圧縮ストロークを大きくとることが好ましい。 The total amount of the compression stroke and the thickness of the resin plate is preferably in the range of 1.01 to 3 times, more preferably in the range of 1.05 to 2 times, still more preferably with respect to the thickness of the target resin plate. The range is 1.1 to 1.8 times. The appropriate value of the compression stroke varies depending on the thickness of the molded body and the melt viscosity of the resin used. For example, when the thickness of the resin plate is 10 mm or more, preferably 12 mm or more, the absolute value of the compression stroke is preferably in the range of 0.2 to 3 mm, more preferably in the range of 0.3 to 2 mm. When the thickness of the molded body is small, it is preferable to increase the compression stroke.
(射出成形により成形体を成形する工程)
金型同士が中間型締め状態に型締めされた金型キャビティ内へ溶融した熱可塑性樹脂を射出した後に最終型締めを行う。この最終型締めは閉鎖されたキャビティ中で行うことも、一部開放されたキャビティ中で行うこともできる。閉鎖されたキャビティとは、樹脂の流動する余地のない閉ざされた状態のキャビティをいう。かかるキャビティは、ホットランナのバルブの閉鎖、および完全なゲートシールにより達成される。更にシリンダー側から付加する樹脂圧力と圧縮圧力との平衡が維持された状態が含まれる。一方、一部開放されたキャビティとは、樹脂の流動する余地がある開放されたキャビティをいう。例えば、オープンノズルで樹脂が大きくフローバックされる場合や、捨てキャビが設けられて樹脂が圧縮によって流入する場合などがある。成形体の品質を安定化させるためより好ましいのは閉鎖されたキャビティにおいて圧縮を行う方法である。
(Process of forming a molded body by injection molding)
Final mold clamping is performed after injecting molten thermoplastic resin into a mold cavity clamped in an intermediate mold clamped state. This final clamping can be done in a closed cavity or in a partially open cavity. A closed cavity refers to a closed cavity with no room for resin flow. Such cavities are achieved by hot runner valve closure and complete gate sealing. Furthermore, the state where the balance between the resin pressure applied from the cylinder side and the compression pressure is maintained is included. On the other hand, a partially opened cavity refers to an opened cavity with room for resin to flow. For example, there is a case where the resin is largely flowed back with an open nozzle, or a case where a waste mold is provided and the resin flows in by compression. In order to stabilize the quality of the molded body, a method in which compression is performed in a closed cavity is more preferable.
最終型締め工程において、可動側金型パーティング面と固定側金型のそれとは接触(以下、“型面タッチ”と称する場合がある)しないことが好ましい。型面タッチがある場合、所定の圧力が樹脂に十分に伝わることがなくなり、寸法精度に優れた低歪みの成形体は得難くなる。可動側金型のパーティング面と固定側金型のそれとの距離は、好ましくは0.05〜3mmの範囲、より好ましくは1〜2mmの範囲である。3mmを超える設定とした場合には成形体の形状によっては可動側金型の倒れが生じ製品にバラツキが生じやすくなる。また0.05mm未満の場合には十分な制御が困難となり、連続の成形において型面タッチが生ずる場合がある。この後、十分に冷却を行った後に成形体を取り出す。 In the final mold clamping step, it is preferable that the movable mold parting surface and the fixed mold are not in contact with each other (hereinafter sometimes referred to as “mold surface touch”). When there is a mold surface touch, the predetermined pressure is not sufficiently transmitted to the resin, and it becomes difficult to obtain a low-distortion molded body having excellent dimensional accuracy. The distance between the parting surface of the movable mold and that of the fixed mold is preferably in the range of 0.05 to 3 mm, more preferably in the range of 1 to 2 mm. If the setting exceeds 3 mm, depending on the shape of the molded body, the movable side mold may fall down, and the product tends to vary. If the thickness is less than 0.05 mm, sufficient control becomes difficult, and a mold surface touch may occur in continuous molding. Thereafter, after sufficiently cooling, the molded body is taken out.
(成形品よりフィルムを剥がす工程)
次に取り出した成形体よりキャリアフィルムを剥がす。成形体よりキャリアフィルムを剥がす方法としては、枚葉のフィルムを用いる場合は手作業にて引き剥がす方法、ロールフィルムを用いる場合はロボットアームにて引き剥がす方法が挙げられる。なお、ロールフィルムを用いる場合ではフィルムを配置した金型の他方の金型に若干のアンダーカット部を設ることにより型開き時に引き剥がす方法も用いることができる。
(Process to remove film from molded product)
Next, the carrier film is peeled off from the molded body taken out. Examples of the method for peeling the carrier film from the molded body include a method for manually peeling when a single film is used, and a method for peeling with a robot arm when a roll film is used. In addition, when using a roll film, the method of peeling off at the time of a mold opening by providing a some undercut part in the other metal mold | die which has arrange | positioned the film can also be used.
本発明の方法を用いて製造された樹脂成形体は大型で厚肉で開口部を有する形状でも良好な外観を有する。したがって、上述のとおり、これらの特性が求められる車両、船舶および航空機などの輸送機器の樹脂製窓(車輌屋根を含む)、並びに液晶ディスプレイ保護材に代表される画像を透視する用途、特にパチンコやピンボールに代表される遊技具における遊技盤に代表される幅広い工業分野において有用である。よってその奏する工業的効果は格別のものである。なお、車輌、船舶および航空機などの輸送機器の樹脂製窓の部材とは、サンルーフやクオータ窓等に代表される光透過性を有する部材のことを指す。また、パチンコやピンボールに代表される遊技具における遊技盤とは、前面盤や遊戯盤等に代表される光透過性を有する部材のことを指す。 The resin molded body produced by using the method of the present invention has a good appearance even when it is large, thick and has an opening. Therefore, as described above, vehicles that require these characteristics, plastic windows (including vehicle roofs) of transportation equipment such as ships and aircraft, and applications for seeing through images typified by liquid crystal display protective materials, particularly pachinko and It is useful in a wide range of industrial fields represented by a game board in a play equipment represented by a pinball. Therefore, the industrial effect produced is exceptional. In addition, the member made of a resin window of a transportation device such as a vehicle, a ship, and an aircraft refers to a member having light transmittance, typified by a sunroof, a quarter window, and the like. In addition, a game board in a game machine represented by pachinko or pinball refers to a light-transmitting member represented by a front board or a game board.
本発明者らが現在最良と考える本発明の形態は、前記の各要件の好ましい範囲を集約したものとなるが、例えば、その代表例を下記の実施例中に記載する。もちろん本発明はこれらの形態に限定されるものではない。 The form of the present invention considered to be the best by the present inventors is a collection of the preferable ranges of the above requirements. For example, typical examples are described in the following examples. Of course, the present invention is not limited to these forms.
以下に実施例を挙げて本発明をさらに具体的に説明する。なお、熱可塑性樹脂及び、表面に機能層を有するフィルムとしては以下のものを用いた。
(I)熱可塑性樹脂
A−1:ポリカーボネート樹脂[帝人化成(株)製パンライトL−1225Y(商品名)]
A−2:ABS樹脂[東レ(株)製920−555(商品名)]
A−3:PMMA樹脂[三菱レイヨン(株)製VH−001(商品名)]
(II)表面に機能層を有するフィルム
B−1:フィルム厚み0.25mmのポリエチレンナフタレート(PEN)フィルムをキャリアフィルムとし、その表面に機能層としてハードコート層を積層したフィルム(融点269℃)[尾池工業(株)製]
B−2:キャリアフィルムの厚みを0.125mmとした以外はB−1と同様のフィルム
B−3:フィルム厚み0.25mmのポリエチレンテレフタレート(PET)フィルムをキャリアフィルムとし、その表面に機能層としてハードコート層を積層したフィルム(融点258℃)
B−4:フィルム厚み0.25mmのポリカーボネート(PC)フィルムをキャリアフィルムとし、その表面に機能層としてハードコート層を積層したフィルム(融点269℃)
B−5: フィルム厚み0.25mmのポリメチルメタクリレート(PMMA)フィルムをキャリアフィルムとし、その表面に機能層としてハードコート層を積層したフィルム(融点180℃)
B−6:キャリアフィルムの厚みを0.05mmとした以外はB−1と同様のフィルム
B−7:キャリアフィルムの厚みを3mmとした以外はB−1と同様のフィルム
The present invention will be described more specifically with reference to the following examples. In addition, the following were used as a thermoplastic resin and the film which has a functional layer on the surface.
(I) Thermoplastic resin A-1: Polycarbonate resin [Panlite L-1225Y (trade name) manufactured by Teijin Chemicals Ltd.]
A-2: ABS resin [920-555 (trade name) manufactured by Toray Industries, Inc.]
A-3: PMMA resin [VH-001 (trade name) manufactured by Mitsubishi Rayon Co., Ltd.]
(II) Film B-1 having a functional layer on the surface: a film in which a polyethylene naphthalate (PEN) film having a film thickness of 0.25 mm is used as a carrier film and a hard coat layer is laminated on the surface as a functional layer (melting point 269 ° C.) [Made by Oike Industry Co., Ltd.]
B-2: A film similar to B-1, except that the thickness of the carrier film is 0.125 mm. B-3: A polyethylene terephthalate (PET) film having a film thickness of 0.25 mm is used as a carrier film, and a functional layer is formed on the surface. Film with a hard coat layer (melting point 258 ° C)
B-4: A film (melting point 269 ° C.) in which a polycarbonate (PC) film having a film thickness of 0.25 mm is used as a carrier film and a hard coat layer is laminated as a functional layer on the surface.
B-5: A film (melting point 180 ° C.) in which a polymethyl methacrylate (PMMA) film having a film thickness of 0.25 mm is used as a carrier film and a hard coat layer is laminated as a functional layer on the surface.
B-6: Film similar to B-1 except that the thickness of the carrier film was 0.05 mm B-7: Film similar to B-1 except that the thickness of the carrier film was 3 mm
[実施例1]
以下の工程に従い、表面に機能層を有する樹脂成形体を作製した。
熱可塑性樹脂(A−1)のペレットを120℃にて5時間熱風乾燥機で乾燥した後、成形機としてシリンダ径110mmφ、型締め力15,700kNの名機製作所製M1600NS−DM射出成形機及び図1の金型を使用し、フィルム(B−1)を用いて射出圧縮成形を行った。
[Example 1]
A resin molded body having a functional layer on the surface was produced according to the following steps.
After drying the pellets of the thermoplastic resin (A-1) with a hot air dryer at 120 ° C. for 5 hours, as a molding machine, a M1600NS-DM injection molding machine manufactured by Meiko Seisakusho with a cylinder diameter of 110 mmφ and a clamping force of 15,700 kN; Using the mold of FIG. 1, injection compression molding was performed using the film (B-1).
該成形機は、特開2003−048241号公報の実施例に記載されたと同じ平行度矯正機構を有するものである。金型取り付け板の四隅に配置された平行度矯正機構の各機構の保持圧力を調整することにより、金型の平行度をtanθが0.00005以下となるよう調整した。 The molding machine has the same parallelism correcting mechanism as that described in the example of Japanese Patent Application Laid-Open No. 2003-084241. By adjusting the holding pressure of each mechanism of the parallelism correcting mechanism disposed at the four corners of the mold mounting plate, the parallelism of the mold was adjusted so that tan θ was 0.00005 or less.
成形はシリンダ温度290℃、ホットランナ設定温度290℃、金型温度は固定側、可動側ともに100℃、中間型締め位置から最終型締め位置までのストロークであるプレスストローク2mm、および圧縮加圧時間180秒で行った。 Molding is cylinder temperature 290 ° C, hot runner set temperature 290 ° C, mold temperature is 100 ° C on both fixed and movable sides, press stroke 2mm, which is the stroke from intermediate clamping position to final clamping position, and compression pressurization time It took 180 seconds.
なお、フィルムは、枚葉にしたフィルムを用い、可動側のパーティング面に両面テープを用いて貼り付けて配置した。
成形体の形状は図1に示すとおり、500mm2以上の開口部を複数個有する、長さ300mm、幅300mm、および厚み10mmの成形体である。
In addition, the film used the sheet | seat made into a sheet | seat, and it affixed and arrange | positioned it on the movable parting surface using the double-sided tape.
As shown in FIG. 1, the shape of the molded body is a molded body having a plurality of openings of 500 mm 2 or more, a length of 300 mm, a width of 300 mm, and a thickness of 10 mm.
[実施例2]
上記実施例1において、成形体の肉厚を30mm、加圧時間を700秒、とした以外は、実施例1と同様にして成形を実施した。
[Example 2]
Molding was performed in the same manner as in Example 1 except that the thickness of the molded body was 30 mm and the pressing time was 700 seconds.
[実施例3]
上記実施例1において、使用するフィルムをフィルム(B−2)とした以外は、実施例1と同様にして成形を実施した。
[Example 3]
In the said Example 1, it shape | molded like Example 1 except having set the film to be used to the film (B-2).
[実施例4]
上記実施例1において、使用樹脂を熱可塑性樹脂(A−2)とし、シリンダ温度250℃、ホットランナ温度250℃、金型温度は固定側可動側ともに60℃とした以外は、実施例1と同様にして成形を実施した。
[Example 4]
Example 1 is the same as Example 1 except that the resin used is thermoplastic resin (A-2), the cylinder temperature is 250 ° C., the hot runner temperature is 250 ° C., and the mold temperature is 60 ° C. on both the fixed and movable sides. Molding was performed in the same manner.
[実施例5]
上記実施例1において、使用樹脂を熱可塑性樹脂(A−3)とし、シリンダ温度250℃、ホットランナ温度250℃、金型温度は固定側可動側ともに60℃とした以外は、実施例1と同様にして成形を実施した。
[Example 5]
Example 1 is the same as Example 1 except that the resin used is a thermoplastic resin (A-3), the cylinder temperature is 250 ° C., the hot runner temperature is 250 ° C., and the mold temperature is 60 ° C. on both the fixed and movable sides. Molding was performed in the same manner.
[実施例6]
上記実施例1において、使用するフィルムをフィルム(B−3)とした以外は、実施例1と同様にして成形を実施した。
[Example 6]
In the said Example 1, it shape | molded like Example 1 except having used the film (B-3) as the film to be used.
[実施例7]
上記実施例1において、使用するフィルムをフィルム(B−4)とした以外は、実施例1と同様にして成形を実施した。
[Example 7]
In the said Example 1, it shape | molded like Example 1 except having used the film (B-4) as the film to be used.
[実施例8]
上記実施例1において、開口部の大きさが30,000mm2である金型(図.2)を用いた以外は実施例1と同様にして成形を実施した。
[Example 8]
Molding was carried out in the same manner as in Example 1 except that a mold having a size of the opening of 30,000 mm 2 (FIG. 2) was used.
[実施例9]
上記実施例1において、流動会合部が偏肉部となるようにした金型(図.3)を用いた以外は実施例1と同様にして成形を実施した。
[Example 9]
Molding was carried out in the same manner as in Example 1 except that a mold (FIG. 3) in which the fluid meeting part was an uneven wall part in Example 1 was used.
[比較例1]
上記実施例1において、フィルムを使用しないこと以外は、実施例1と同様にして成形を実施した。
[Comparative Example 1]
In Example 1 above, molding was carried out in the same manner as Example 1 except that no film was used.
[比較例2]
上記実施例1において、使用するフィルムをフィルム(B−5)とした以外は、実施例1と同様にして成形を実施した。なお、比較例2ではフィルムが成形体に融着したため剥がすことができず、鉛筆硬度は測定できなかった。
[Comparative Example 2]
In the said Example 1, it shape | molded like Example 1 except having used the film (B-5) as the film to be used. In Comparative Example 2, the film was fused to the molded body and thus could not be peeled off, and the pencil hardness could not be measured.
[比較例3]
上記実施例1において、使用するフィルムをフィルム(B−6)とした以外は、実施例1と同様にして成形を実施した。
[Comparative Example 3]
In the said Example 1, it shape | molded like Example 1 except having used the film (B-6) as the film to be used.
[比較例4]
上記実施例9において、使用するフィルムをフィルム(B−6)とした以外は実施例9と同様にして成形を実施した。
[Comparative Example 4]
In Example 9, the molding was carried out in the same manner as in Example 9 except that the film used was a film (B-6).
[比較例5]
上記実施例1において、使用するフィルムをフィルム(B−7)とした以外は、実施例1と同様にして成形を実施した。
[Comparative Example 5]
In the said Example 1, it shape | molded like Example 1 except having used the film (B-7) as the film to be used.
(III)評価項目
(III−1)形状
フィルムがついた成形体の形状を観察し、下記の通り評価を実施した。
○:成形体の金型形状の転写が十分であった。
×:フィルムと金型との密着が不十分なため、成形体の金型形状の転写が不十分であった。
(III−2)ウエルドライン
成形体のウエルドラインの有無を観察し、下記の通り評価を実施した。
○:ウエルドラインが認められなかった。
×:ウエルドラインが認められた。
(III−3)鉛筆硬度
成形体の耐擦傷性の目安としてJIS K 5600−5−4に示される鉛筆硬度の評価を実施した。
(III−4)シワ
成形体シワの有無を観察し、下記の通り評価を実施した。
1:無数のシワが有る
2:シワが樹脂会合部に有る
3:シワは無いが若干凹状
4:シワ無し良好
(III−5)フィルムの成形体への融着
成形体をSEMにて観察し、キャリアフィルムの融着の有無について下記の通り評価を実施した。また、FT−IRを用いてフィルムの劣化状態を確認した。
1:フィルムが成形体に融着し剥がせない
2:フィルムが成形体に融着し剥がし難い
3:融着は無いが若干フィルムの劣化有り
4:融着無し良好
実施例1〜9および比較例1〜5の評価結果を表1に記載した。
(III) Evaluation Items (III-1) Shape The shape of the molded body with the film was observed and evaluated as follows.
○: The mold shape of the molded body was sufficiently transferred.
X: Since the adhesion between the film and the mold was insufficient, transfer of the mold shape of the molded product was insufficient.
(III-2) Weld line The presence or absence of the weld line of the molded body was observed and evaluated as follows.
○: Weld line was not recognized.
X: A weld line was observed.
(III-3) Pencil Hardness As an index of the scratch resistance of the molded article, the pencil hardness shown in JIS K 5600-5-4 was evaluated.
(III-4) Wrinkles The presence or absence of wrinkles on the molded product was observed and evaluated as follows.
1: There are innumerable wrinkles 2: There are wrinkles in the resin meeting part 3: There are no wrinkles but some concaves 4: Good without wrinkles (III-5) Fusing of the film to the molded body The molded body was observed with SEM Then, the following evaluation was performed on the presence or absence of fusion of the carrier film. Moreover, the deterioration state of the film was confirmed using FT-IR.
1: The film is fused to the molded body and cannot be peeled away 2: The film is fused to the molded body and is difficult to peel away 3: There is no fusion but there is a slight deterioration of the film 4: Good without fusion Fusion Examples 1 to 9 and comparison The evaluation results of Examples 1 to 5 are shown in Table 1.
1 可動側金型(固定側金型と額縁構造となる)
2 額縁ブロック
3 開口部成形用押し当て式入れ子
4 固定側金型
5 フィルム
6 溶融樹脂
7 成形体本体
8 成形体開口部
9 成形体開口部
10 成形体偏肉部
11 偏肉部成形用入れ子
1 Movable side mold (becomes fixed side mold and frame structure)
DESCRIPTION OF
Claims (10)
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JP2008071416A JP5296400B2 (en) | 2008-03-19 | 2008-03-19 | Method for producing resin molded body having surface functional layer and molded body thereof |
CN200910128236.2A CN101537689B (en) | 2008-03-19 | 2009-03-18 | Method for manufacturing resin forming body with surface functional layer and forming body thereof |
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Cited By (3)
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JP2011218603A (en) * | 2010-04-06 | 2011-11-04 | Teijin Chem Ltd | Molding method for resin molded body with surface functional layer, and the molded body |
JP2017119401A (en) * | 2015-12-28 | 2017-07-06 | 株式会社クラレ | Method for manufacturing injection molding |
CN113977820A (en) * | 2021-11-04 | 2022-01-28 | 株洲时代瑞唯减振装备有限公司 | Mold opening and closing method of vulcanizing machine mold and vulcanizing machine mold convenient for demolding |
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CN102555153B (en) * | 2010-12-20 | 2014-07-09 | 宝理塑料株式会社 | Composite forming body, production method thereof and in-mould label |
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JP2011218603A (en) * | 2010-04-06 | 2011-11-04 | Teijin Chem Ltd | Molding method for resin molded body with surface functional layer, and the molded body |
JP2017119401A (en) * | 2015-12-28 | 2017-07-06 | 株式会社クラレ | Method for manufacturing injection molding |
CN113977820A (en) * | 2021-11-04 | 2022-01-28 | 株洲时代瑞唯减振装备有限公司 | Mold opening and closing method of vulcanizing machine mold and vulcanizing machine mold convenient for demolding |
CN113977820B (en) * | 2021-11-04 | 2023-06-23 | 株洲时代瑞唯减振装备有限公司 | Mold opening and closing method of vulcanizing machine mold and vulcanizing machine mold convenient to demolding |
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JP5296400B2 (en) | 2013-09-25 |
CN101537689B (en) | 2014-08-13 |
CN101537689A (en) | 2009-09-23 |
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