JP2010052353A - Transfer sheet having hairline design, and method of manufacturing transfer molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a transfer molded product excellent in designability, which has a beautiful hairline texture free of defective appearance due to remains of shavings on the surface. <P>SOLUTION: A transfer sheet 1 for forming the transfer molded product is formed by laminating a transfer layer 7 and a hairline forming layer 3 made of a hardening resin on a substrate sheet 2, and forming the hairline texture on a boundary surface of the hairline forming layer and the transfer layer. The method of manufacturing the transfer molded product includes arranging the transfer sheet in a die so that a surface of the substrate sheet faces a die cavity, funnelling a molding resin in the die, and peeling the substrate sheet 2 after cooling and solidifying. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a transfer sheet for producing a transfer molded article having a hairline design composed of fine irregularities, which can be used for, for example, automobile interior parts and automobile exterior parts that require a high-quality appearance, and the transfer sheet. The present invention relates to a transfer molded product formed using

  Conventionally, as a method for obtaining a resin plate having a hairline and a resin molded product, there is a method using a transfer sheet 101 as shown in FIG. The transfer sheet 101 has a hairline 107 formed on one surface of a substrate sheet 102 having releasability by polishing, and a release layer 103, a decorative layer 104, and an adhesive layer 105 are sequentially stacked thereon as a transfer layer 106. It is. A method for obtaining the transfer molded product 111 using the transfer sheet 101 will be briefly described. First, the transfer sheet 101 is adhered to the surface of the resin molded product 108. Then, the base sheet 102 is peeled off and the transfer layer 106 is transferred onto the surface of the resin molded product 108, thereby forming the transfer molded product 111 having the hairline 107 on the outermost surface (see FIG. 6).

JP 11-227394 A

  In order to form a hairline having a high design property, it is necessary to set the unevenness difference of the hairline to about 3 μm. However, if the unevenness of the hairline is given to the base sheet 102 so deeply, the shavings 121 generated at the time of processing the hairline may not be cut from the base sheet 102 and may remain on the base sheet 102 in a thread form. It was. If the shavings 121 remain in the form of a thread on the base sheet 102, the traces of the shavings 121 remain on the hairline stitches 107 on the surface of the transfer layer 106. The appearance defect that the mark appears was generated (see FIG. 6).

  It is an object of the present invention to provide a transfer sheet for obtaining a transfer molded product excellent in the design of hairlines without appearance defects due to traces of shavings generated during processing of the hairlines.

  In order to achieve the above object, the present invention has the following features.

  In the transfer sheet for forming a transfer molded product of the present invention, a hairline forming layer made of a curable resin and a transfer layer are laminated on a base sheet, and hairlines are formed on the boundary surface between the hairline forming layer and the transfer layer. It is a configuration.

  Moreover, in said invention, the thickness of a hairline formation layer may be thicker than the uneven | corrugated difference of the hairline eyes.

  Moreover, in said invention, 2-5 micrometers may be sufficient as the unevenness | corrugation difference of a hairline.

  Moreover, in said invention, the thickness of a hairline formation layer may be 1-3 micrometers thick from the uneven | corrugated difference of the hairline eyes.

  The method for producing a transfer molded product of the present invention comprises transferring the transfer sheet of any of the above inventions by bringing the transfer layer side into close contact with the surface of the resin molded product and applying heat and pressure from the base sheet side of the transfer sheet. And a step of peeling the base sheet after the layer is adhered to the surface of the resin molded product.

  The method for producing a transfer molded product of the present invention comprises arranging the transfer sheet of any one of the above inventions in a mold so that the surface of the base sheet on which the transfer layer is not formed faces the mold cavity. A molding resin is poured into the mold, and the substrate sheet is peeled off after cooling and solidification.

  According to the transfer sheet of the present invention, hairlines are formed on the hairline forming layer made of a curable resin. Therefore, since no shavings remain on the substrate sheet side, no traces of shavings remain on the hairline on the surface of the transfer layer, and as a result, the design of a beautiful hairline with no appearance defects due to the traces of shavings on the surface Can be obtained.

  Embodiments of the present invention will be described in detail with reference to the drawings.

  First, the transfer sheet 1 of the present invention will be described (see FIG. 1).

  The transfer sheet 1 is formed by laminating a hairline forming layer 3 and a transfer layer 7 made of a curable resin on a base sheet 2 and forming a hairline 8 at the boundary surface between the hairline forming layer 3 and the transfer layer 7. As the transfer layer 7, a release layer 4, a decorative layer 5, and an adhesive layer 6 are usually formed.

  As the base sheet 2, polyester resin, polypropylene resin, vinyl chloride resin, polyethylene resin, polyethylene terephthalate resin, polycarbonate resin, nylon resin, vinylon resin, acetate resin, polyethylene resin, polyamide resin, polyacrylic resin, Plastic sheets such as polyvinyl chloride resins can be used. The thickness of the base sheet 2 is preferably 10 to 100 μm, but more preferably 75 to 100 μm so as not to curl due to the shrinkage of the hairline forming layer 3 described later.

  The hairline forming layer 3 is a layer for forming the hairline eye 8. As the hairline forming layer 3, a curable resin such as an epoxy resin, an epoxy melamine resin, an amino alkyd resin, a melamine resin, a silicone resin, a fluororesin, a cellulose derivative, a urea resin, a polyolefin resin, and paraffin can be used. Examples of the method for forming the hairline forming layer 3 include a coating method such as a roll coating method and a spray coating method, a printing method such as a gravure printing method and a screen printing method.

  As a method for forming the hairline stitch 8, there is a method in which the surface of the hairline forming layer 3 formed on the base sheet 2 that is continuously fed is cut into a hairline shape with sandpaper. Since the hairline forming layer 3 is formed of the above-described resin, the shavings of the hairline forming layer 3 are in powder form and are easily detached from the hairline forming layer 3. Accordingly, the hairline 8 on the surface of the transfer layer 7 formed on the hairline forming layer 3 has no appearance defect due to traces of shavings and has excellent design. The unevenness difference of the hairline 8 is preferably 2 to 5 μm. If it is less than 2 μm, sufficient unevenness cannot be obtained, and if it exceeds 5 μm, the peelability between the hairline forming layer 3 and the transfer layer 7 is deteriorated, and a part of the surface of the transfer layer 7 becomes the hairline forming layer 3. This is because when the transfer layer 7 is peeled off in the remaining state, the shape of the hairline 8 is lost and the design is impaired. Further, in order to prevent the hairline 8 from reaching the base sheet 2 and scraping the base sheet 2, it is important to set the thickness of the hairline forming layer 3 to be thicker than the unevenness of the hairline 8. More specifically, the thickness of the hairline forming layer 3 is preferably increased by 1 to 3 μm from the unevenness of the hairline eyes 8. If the difference between the unevenness of the hairline 8 and the thickness of the hairline forming layer 3 is less than 1 μm, the unevenness of the unevenness of the hairline 8 can not be absorbed and the substrate sheet 2 is locally scraped and shaved into the hairline If the thickness exceeds 3 μm, the hairline forming layer 3 becomes thicker than necessary, and drying takes time, resulting in poor productivity.

  As the transfer layer 7, the release layer 4 may be formed as necessary in order to ensure the release from the hairline forming layer 3. The peeling layer 4 is a layer which peels from the hairline forming layer 3 and becomes the outermost surface of the transfer object when peeling the base sheet 2 and the hairline forming layer 3. The release layer 4 may be made of acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, or vinyl chloride-vinyl acetate copolymer. Copolymers such as system resins and ethylene-vinyl acetate copolymer resins may be used. When the release layer 4 requires hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used. Examples of the method for forming the release layer 4 include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

  As a material of the decoration layer 5, resins such as polyvinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, and alkyd resin are used. A colored ink containing a suitable color pigment or dye as a colorant may be used as a binder. As a method for forming the decorative layer 5, a normal printing method such as a gravure printing method, a screen printing method, or an offset printing method may be used. As thickness of the decoration layer 5, 1-30 micrometers is preferable. The decorative layer 5 is not limited to colored ink, and may form a metal vapor deposition layer or the like to express a design with metallic luster. Aluminum, chromium, copper, tin, or the like is used as the material for the metal deposition layer. The metal vapor deposition layer may be formed by using a vacuum vapor deposition method, a sputtering method, an ion plating method, or the like.

  Moreover, you may form the contact bonding layer 6 as needed. The adhesive layer 6 is a layer for adhering the transfer sheet to the resin molded product 9 by a transfer method or a simultaneous molding transfer method described later. When the material of the resin molded product 9 is a polyacrylic resin, a polyacrylic resin may be used as the material of the adhesive layer 6. In addition, when the material of the resin molded product 9 is polyphenylene oxide / polystyrene resin, polycarbonate resin, styrene copolymer resin, or polystyrene blend resin, polyacrylic resin or polystyrene resin having affinity with these resins Polyamide resin or the like may be used as the material for the adhesive layer 6. As a method for forming the adhesive layer 6, it is preferable to use a gravure coating method, a roll coating method, a comma coating method, a gravure printing method, a screen printing method, or the like. The dry film thickness of the adhesive layer 6 is generally 1 to 5 μm.

  Next, a method for producing a transfer molded article 11 (see FIG. 4) using the transfer sheet 1 will be described.

  Examples of the thermoplastic resin used in the resin molded product 9 for forming the transfer molded product 11 include polyolefin resins such as polyethylene and polypropylene, polystyrene resins, polyvinyl chloride resins, poly (meth) acrylate resins, Any known thermoplastic resins such as acrylic resins, polyacetal resins, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyamide resins, polycarbonate resins, polyphenylene sulfide resins and polyimide resins can be used. These resins can be used alone or in admixture of two or more.

  The transfer process of transferring the transfer layer 7 from the transfer sheet 1 onto the resin molded product 9 by the transfer method is performed as follows (see FIG. 2). First, the transfer layer 7 side of the transfer sheet 1 is brought into close contact with the surface of the resin molded product 9. Next, using a transfer machine such as a roll transfer machine or an up-down transfer machine provided with a heat-resistant rubber-like elastic body 21 such as silicon rubber, the heat-resistant rubber is set at a temperature of about 80 to 260 ° C. and a pressure of about 500 to 2000 Pa. Heat and pressure are applied from the substrate sheet 2 side of the transfer sheet 1 through the elastic body 21. By doing so, the transfer layer 7 adheres to the surface of the resin molded product 9. Finally, when the base sheet 2 is peeled off after cooling, the transfer layer 7 is transferred to the surface of the resin molded product 1 and the transfer process is completed.

  The transfer process of transferring the transfer layer 7 from the transfer sheet 1 onto the resin molded product 9 by the simultaneous molding transfer method is performed as follows (see FIG. 3). First, the transfer sheet 1 is fed into a molding die 31 composed of a movable die and a fixed die so that the surface on which the transfer layer 7 is not formed faces the die cavity. At that time, the sheet-like transfer sheets 1 may be fed one by one, or necessary portions of the long transfer sheet 1 may be intermittently fed. When the long transfer sheet 1 is used, the transfer sheet 1 is placed in the mold so that the registration of the transfer sheet 1 and the molding die 31 coincide with each other using a feeding device having a positioning mechanism. Good. Further, when the transfer sheet 1 is intermittently fed, the transfer sheet 1 may be fixed by a movable mold and a fixed mold after the position of the transfer sheet 1 is detected by a sensor. After the molding die 31 is closed, the molding resin 32 is injected and filled from the gate into the die and then cooled and solidified to form the resin molded product 9, and at the same time, the transfer sheet 1 is adhered to the surface (see FIG. 3 (a)). After the resin molded product 9 is cooled, the molding die 31 is opened and the resin molded product 9 is taken out. Finally, when the base sheet 2 is peeled off, a transfer molded product 11 in which the transfer layer 7 is transferred onto the surface of the resin molded product 9 is formed (see FIG. 3B).

  This transfer molded product 11 is excellent in the design of the hairline eye 8 without appearance defects due to traces of shavings generated during processing of the hairline eye 8.

  A polyethylene terephthalate film having a thickness of 75 μm was used as the base sheet 2, and an epoxy melamine resin was formed as the hairline forming layer 3 to a thickness of 4 μm by a gravure printing method. Next, the surface of the hairline forming layer 3 was shaved with sandpaper to form a hairline 8 having an unevenness difference of 3 μm. The shavings of the hairline forming layer 3 became powdery and easily separated from the hairline forming layer 3, and beautiful hairline eyes 8 were formed on the hairline forming layer 3. The release layer 4, the decorative layer 5, and the adhesive layer 6 were sequentially formed on the hairline forming layer 3 by the gravure printing method, whereby the release layer 4, the decorative layer 5 and the adhesive layer 6 were laminated as the transfer layer 7. A transfer sheet 1 was obtained. Here, the release layer 4 was made of polyurethane ink, the decorative layer 5 was made of acrylic ink, and the adhesive layer 6 was made of vinyl chloride-vinyl acetate copolymer ink (see FIG. 1).

  The transfer sheet 1 formed in this way is placed in the mold so that the surface of the base sheet 2 on which the transfer layer 7 is not formed faces the mold cavity, and is clamped and then molded in the mold. The resin 32 was poured and cooled and solidified to obtain a resin molded product 9. The base sheet 2 was peeled from the obtained resin molded product 9 to obtain a transfer molded product 11 having a transfer layer 7 on the surface (see FIG. 3).

  The transfer molded article 11 obtained in this way had beautiful hairline eyes 8 with no appearance defects due to traces of shavings on the surface, and was excellent in design (see FIG. 4).

It is sectional drawing which shows the transfer sheet of this invention. It is sectional drawing which shows the method of providing a transfer layer on the surface of a resin molded product by the transfer method. It is sectional drawing which shows the method of providing a transfer layer on the surface of a resin molded product by the simultaneous molding transfer method. It is sectional drawing which shows the transcription | transfer molded product of this invention. It is sectional drawing which shows the conventional transfer sheet. It is sectional drawing which shows the conventional transcription | transfer molded product.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transfer sheet 2 Base sheet 3 Hairline formation layer 4 Release layer 5 Decorating layer 6 Adhesive layer 7 Transfer layer 8 Hairline 9 Resin molded product 11 Transfer molded product 21 Heat-resistant rubber-like elastic body 31 Mold 32 Molding resin 101 Transfer Sheet 102 Base sheet 103 Peeling layer 104 Decorating layer 105 Adhesive layer 106 Transfer layer 107 Hairline stitch 108 Resin molded product 111 Transfer molded product 121 Shavings

Claims (6)

  A hairline forming layer made of a curable resin and a transfer layer are laminated on a base sheet, and a hairline is formed at the boundary surface between the hairline forming layer and the transfer layer. Transfer sheet.   The transfer sheet according to claim 1, wherein the thickness of the hairline forming layer is thicker than the unevenness difference of the hairline.   The transfer sheet according to claim 1 or 2, wherein the unevenness of the hair line is 2 to 5 µm.   The transfer sheet according to claim 1, wherein the thickness of the hairline forming layer is 1 to 3 μm thicker than the unevenness of the hairline.   The transfer sheet according to any one of claims 1 to 4, wherein the transfer layer side is adhered to the surface of the resin molded product, and heat and pressure are applied from the base sheet side of the transfer sheet to the surface of the resin molded product. A method for producing a transfer molded article, comprising peeling off the base sheet after bonding.   The transfer sheet according to any one of claims 1 to 4 is placed in a mold such that a surface of a base sheet on which a transfer layer is not formed faces a mold cavity, and a molding resin is poured into the mold. A method for producing a transfer molded product, wherein the substrate sheet is peeled off after cooling and solidification.

Images