JP2010125800A - Method for producing decorative sheet having metal tone glossy pattern and method for producing in-mold decorative molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a decorative sheet having a glossy metal-tone pattern which prevents the occurrence of corrosion and rust in a thin metal film layer due to residual water and the problem of waste liquid treatment when the thin metal film layer is pattern-formed, and to provide a method for producing an in-mold decorative molded product. <P>SOLUTION: In the method for producing the decorative sheet, the decorative sheet 40, where a pattern layer 24 is formed on a first base sheet 20, and a thin metal film forming sheet 6, where the thin metal film layer 16 is formed on a second base sheet 10 having mold-release properties, are laminated, and the metal thin film layer 16 is transferred from the metal thin film forming sheet 6, and formed on the surface of the first base sheet 20 on which the pattern layer 24 is formed. The transfer/formation of the metal thin film layer is carried out by an on-demand print method. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a decorative sheet including a metallic luster pattern used for a decorative part of an automobile part, an electrical product, a communication device, an audio device, and the like, and a method for manufacturing a molded simultaneous decorative molded product.

  The decorative sheet for the above uses is required not only for the color color of a normal pigment ink layer but also for the design of metallic luster by a metal thin film layer or the like as pattern formation. And as a method of patterning a metal thin film layer on such a decorative sheet, for example, as in Patent Document 1 below, a water-soluble resin layer is patterned, and the metal thin film layer is formed by means such as vacuum deposition. There was a method of forming a pattern by removing an unnecessary metal thin film layer by washing with water after being formed on the entire surface.

JP-A-8-337097

  However, the decorative sheet obtained by the method as disclosed in Patent Document 1 has a problem that corrosion and rust are likely to occur in the metal thin film layer due to an adverse effect of residual moisture in the washing treatment. Moreover, when it removed by the water washing process, there also existed a troublesome problem which had to process the removed waste liquid.

  The present inventors solved the above-mentioned problems by the following invention. That is, the present invention is a laminate of a decorative sheet having a pattern layer formed on a first base sheet and a metal thin film forming sheet having a metal thin film layer formed on a second base sheet having releasability, A method for producing a decorative sheet including a metallic gloss pattern in which the metal thin film layer is transferred and formed from the metal thin film forming sheet onto the surface of the first base sheet on which the pattern layer is formed, the metal thin film layer This is characterized in that the transfer formation of the print was performed on demand.

  In the above configuration, the on-demand printing method is a thermal transfer printer method in which heat is applied from the back surface of the metal thin film forming sheet.

  Further, in each of the above configurations, a position detection pattern for pattern transfer forming the metal thin film layer from the metal thin film forming sheet to a predetermined position on the surface of the first base sheet on which the pattern layer is formed is It is pre-formed on the first base sheet before forming.

  In each of the above structures, an adhesive layer is formed as an uppermost layer after the transfer of the metal thin film layer.

  Moreover, this invention inserts the decorating sheet | seat containing the metallic luster pattern obtained by the manufacturing method in any one of said to the shaping die which consists of A metal mold | die and B metal mold | die, A metal mold | die surface And the surface opposite to the pattern layer forming side of the first base sheet are fixed, and a molding resin is injected from the B mold to form a pattern layer and a metal thin film layer on the surface simultaneously with molding. It is a method for producing a simultaneously molded decorative molded product, characterized in that after the molded simultaneous decorated molded product is obtained and cooled, the decorated molded product is taken out from the mold.

  The decorative sheet containing a metallic luster pattern obtained by the present invention does not contain a water washing process when patterning the metal thin film layer, so there is no residual moisture, and the metal thin film layer is corroded or rusted by residual moisture. There is no. And since the water washing process is not included, there exists an effect that the problem of a waste liquid process does not generate | occur | produce at all. Further, since the metal thin film layer formed in the present invention is patterned on demand, there is an effect that it is possible to form the plate efficiently without the need for producing a plate.

  Furthermore, in the method for producing a simultaneously molded decorative molded product of the present invention, the decorative sheet containing the metallic gloss pattern described above is inserted into a molding die composed of an A die and a B die, and the surface of the A die And the surface opposite to the pattern layer forming side of the first base sheet are fixed, and a molding resin is injected from the B mold to form a pattern layer and a metal thin film layer on the surface simultaneously with molding. It is characterized in that a simultaneously decorated decorative molded product is obtained, and after cooling, the decorative molded product is taken out from the molding die. Therefore, there exists an effect which can obtain easily the shaping | molding simultaneous decoration molded product in which the metal thin film layer was patterned.

  According to the present invention, the decorative sheet in which the pattern layer is formed on the first base sheet and the metal thin film forming sheet in which the metal thin film layer is formed on the second base sheet having releasability are laminated, A method for producing a decorative sheet including a metallic gloss pattern in which the metal thin film layer is transferred and formed from the metal thin film forming sheet onto the surface of the first base sheet on which the pattern layer is formed, the metal thin film layer The present invention provides a method for producing a decorative sheet including a metallic luster pattern, which is an on-demand printing method.

  As the material of the first base sheet of the decorative sheet, resin films such as acrylic, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, polypropylene, polyamide, polyurethane, polyvinyl chloride, and polyvinyl fluoride are mainly used. The thickness of the resin film can be appropriately set in the range of 4 to 800 μm. If the thickness is less than 4 μm, the strength of the layer is insufficient and the layer is torn when it is peeled off, making it difficult to handle. If the thickness exceeds 800 μm, the substrate sheet layer is too rigid and difficult to process. When a decorative sheet containing a metallic luster pattern is used as a transfer sheet, a resin such as silicon, melamine, or acrylic is printed on the resin film, such as gravure printing, screen printing, flexographic printing, reverse coating, etc. It is preferable to form a base sheet layer having a releasability by applying the coating method.

  The picture layer as used in the present invention is a layer excluding a metal thin film layer from a specific pattern composed of a desired color design pattern or an abstract pattern such as wood or stone, and gravure printing or offset printing. It can be provided by various general printing methods such as screen printing. The material of the picture layer is made of, for example, a binder resin such as acrylic, polyester, polyurethane, or polyvinyl chloride, and a colorant or additive such as various pigments, dyes, or metal powders.

  The thickness of the pattern layer can be appropriately set within a range of 0.1 to 300 μm. If the thickness is less than 0.1 μm, the strength and color as a layer are insufficient, and if the thickness exceeds 300 μm, the flexibility as the layer is lost and processing becomes difficult.

  Note that a peeling layer, an anchor layer, or the like may be provided between the pattern layer and the first base sheet, or an anchor layer, an adhesive layer, or the like may be provided on the pattern layer. The release layer includes polyacrylic resins, polyester resins, polyvinyl chloride resins, cellulose resins, rubber resins, polyurethane resins, polyvinyl acetate resins, and vinyl chloride-vinyl acetate copolymer resins. Copolymers such as ethylene-vinyl acetate copolymer resin may be used. As the anchor layer, two-component cured urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, polyacrylic resin, epoxy resin, vinyl resin A polymer resin or the like may be used. As the adhesive layer, polyacrylic resin, polystyrene resin, polyamide resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, coumarone indene resin, or the like may be used. As a method for forming these layers, there are a coating method such as a gravure coating method, a roll coating method, a comma coating method, and a lip coating method, and a printing method such as a gravure printing method and a screen printing method.

  As the material of the second base sheet of the metal thin film forming sheet, like the first base sheet, acrylic, polycarbonate, polyester, polybutylene terephthalate, polypropylene, polyamide, polyurethane, polyvinyl chloride, polyvinyl fluoride, etc. A resin film can be used. The said resin film thickness can be suitably set in the range of 5-800 micrometers. If the thickness is less than 5 μm, the strength as a base sheet is insufficient and tears at the time of peeling, and handling becomes difficult. On the other hand, if the thickness exceeds 800 μm, the rigidity is too high and processing becomes difficult. In order to impart releasability to the resin film, a resin such as silicon, melamine, or acrylic is applied on the resin film.

  The metal thin film layer of the metal thin film forming sheet is a layer mainly containing a metal that does not contain a resin binder. 2 formed on almost the entire surface of the base sheet. Examples of the material for the metal thin film layer include aluminum, chromium, tin, nickel, indium, silicon, copper, silver, gold, titanium, stainless steel, brass, tin oxide, indium oxide, silicon oxide, and zinc sulfide. The thickness of the metal thin film layer can be appropriately set in the range of 50 to 1200 mm. If the thickness is less than 50 mm, the metallic luster hardly develops, and if the thickness exceeds 1200 mm, cracks are likely to occur.

  The metal thin film layer may be transferred by an on-demand printing method. “On demand” means “according to the request”, and the on-demand printing method is a system that prints only the required number of copies when necessary. In general, it is convenient when printing only a small number of copies, such as when you want to output printed materials with many revisions or changes that are only partially changed, and it is often used when outputting things that do not need to be printed in large quantities. The thin metal film layer was used as a method for forming various patterns. Since the washing process is not included when forming the pattern of the metal thin film layer, the metal thin film layer is not corroded or rusted by residual moisture, and the problem of waste liquid treatment does not occur at all. Further, it is possible to form the plate efficiently without the need for producing a plate.

  A release layer may be provided between the second base sheet layer and the metal thin film layer of the metal thin film forming sheet. An anchor layer may be provided between the release layer and the metal thin film layer. As the material and the forming method of the peeling layer and the anchor layer, the same materials as those formed on the first base sheet can be used.

  A specific example of the on-demand printing method is a thermal transfer printer method in which heat is applied from the back surface of the metal thin film forming sheet, that is, the surface opposite to the metal thin film layer forming surface.

  FIG. 8 shows an outline of a thermal transfer portion of a general thermal transfer printer, in which 91 is a thermal head, 92 is a platen roller, 93 is an ink sheet driving roller, 94 is an ink sheet, and 95 is a recording paper. As described above, the ink sheet 94 and the recording paper 5 are sandwiched between the platen roller 92 and the heating resistance element of the thermal head 91, and the platen roller 92 rotates to convey the ink sheet 94 and the recording paper 95. At the same time, the heating resistance element of the thermal head 91 is selectively heated according to the recording information, and the ink on the ink sheet 94 is thermally transferred to the recording paper 95. Each time the recording for one line is completed, the ink sheet 94 is conveyed by the ink sheet driving roller 93 in a direction different from the traveling direction of the recording paper 95, and the ink sheet 94 is peeled off from the recording paper 95 and recording is performed sequentially. Is. In the present invention, the metal thin film forming sheet is used as the ink sheet 94, and the decorative sheet is used as the recording paper 95.

  The thermal head 91 is generally formed by forming a thick film resistor (heat generating element) on the substrate surface by a method such as screen printing, and further through an electrode connected to the resistor through a lead wire connected thereto. Although the resistor generates heat when energized, the substrate of the thermal head 9 suitable for the present invention is alumina having a width of 200 mm to 1000 mm, which is wider than a commercially available one having a width of several tens to 200 mm. The thing made from ceramics represented by is preferable. The larger width is preferable for the above-mentioned application, but when the width is 1000 mm or more, problems such as non-uniform spacing between the dots of the resistor occur. The resolution is preferably about 300 to 800 dpi per inch. This is because if it is less than 300 dpi per inch, the metallic gloss of the metal thin film layer is lowered, and if it is 800 dpi or more, it takes time to form a transfer and productivity is lowered.

  In addition, it is preferable to form a position detection pattern having a size of, for example, about 3 to 10 mm square on the first base sheet. This is because, if this position detection pattern is read by an optical method, the metal thin film layer on the second base sheet can be transferred to a predetermined position on the pattern layer of the first base sheet.

  Further, in the method for producing a decorative sheet including a metallic gloss pattern of the present invention, after the metal thin film layer is transferred and formed on the pattern layer, an adhesive layer may be applied partially or entirely as the uppermost layer. Good. As the adhesive layer, a heat-sensitive and pressure-sensitive resin suitable for the material of the adherend is appropriately used. For example, when the material of the adherend is a polyacrylic resin, a polyacrylic resin may be used. In addition, when the material of the adherend is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, a polyacrylic resin, a polystyrene resin having an affinity for these resins, A polyamide resin or the like may be used. Furthermore, when the material of the adherend is a polypropylene resin, a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a cyclized rubber, or a coumarone indene resin can be used. Examples of the method for forming the adhesive layer include a coating method such as a gravure coating method, a roll coating method, a comma coating method, and a lip coating method, and a printing method such as a gravure printing method and a screen printing method.

  The decorative sheet containing a metallic gloss pattern obtained by the above method is inserted into a molding die composed of an A die and a B die, and the surface of the A die and the pattern layer forming side of the first base sheet are Fix it so that the surface on the opposite side is in contact, inject the molding resin from the B mold, and after cooling, take out the decorative molded product from the molding mold to form a pattern layer and metal thin film layer on the surface at the same time as molding It is possible to obtain a molded and decorated decorative molded product.

  Examples of the molding resin used include acrylic, polycarbonate, acrylonitrile butadiene styrene, polypropylene, polyurethane, polyarylate, polystyrene, and polyethylene.

  Example 1 First, a metal thin film forming sheet was prepared according to the following procedure. A release resin layer 11 is formed by applying a silicone resin to one side of a 12 μm thick biaxially stretched polyethylene terephthalate film (F-55, hereinafter referred to as “PET film”) as the second substrate sheet 10 and thermosetting it. Then, a release layer 13 was formed thereon with an acrylic resin manufactured by Inktec Co., Ltd.

  Next, Sakata Inx Co., Ltd. Lamiol Mark 3 was applied onto the release layer 13 by gravure printing, dried with hot air to form a resin layer having a thickness of 2 μm, and then dried at 170 ° C. for 20 seconds and 200 seconds. Baking was performed under two conditions of 20 ° C. for 20 seconds to form the front anchor layer 15. Next, a metal thin film layer 16 of aluminum having a thickness of 800 mm was formed on the entire surface of the front anchor layer 15 by vacuum deposition. Next, a rear anchor layer 19 was formed by a gravure printing method using Dainichi Seika Kogyo Co., Ltd. Lamic F-220 to obtain a metal thin film forming sheet 6 (see FIG. 1).

  Next, the decorative sheet 40 was created by the following procedure. A biaxially stretched polyethylene terephthalate film (F-55 manufactured by Toray Industries, Inc.) having a thickness of 50 μm is used as the first base sheet 20, and a release resin 21 is formed by applying a silicone resin on one side and thermally curing the film. A release layer 23 was formed on the top with an acrylic resin manufactured by Inktec Co., Ltd.

  Next, using a Toyo Ink Co., Ltd. Real Color and Toyo Ink Co., Ltd. Fine Star, a pattern layer 24 and a 5 mm square position detection pattern 25 were formed by a multicolor gravure printing machine (see FIG. 2).

  Thereafter, the metal thin film forming sheet 6 was laminated so that the pattern layer 24 and the rear anchor layer 19 were in contact with each other, and heat was applied from the back surface of the metal thin film forming sheet 6 by a thermal head 91 of a thermal transfer printer (see FIG. 3). The thermal head 91 used was made of ceramic having a width of 500 mm and a resolution of 600 dpi per inch. The position detection pattern 25 is read by an optical method, the thermal head 91 is arranged at a desired position, heat is applied only to a necessary portion, and a part of the metal thin film layer 16 on the metal thin film forming sheet 6 is first base sheet. The pattern was transferred to predetermined positions on the 20 pattern layers 24.

  Next, the rear anchor layer 19, the metal thin film layer 16, the front anchor layer 15, and the release layer 13 are formed on the pattern layer 24 by peeling the metal thin film forming sheet 6 while unwinding the laminated sheet from the paper tube. The decorative sheet 4 including the metallic gloss pattern thus obtained was obtained (see FIG. 4). Furthermore, the adhesive layer 29 was formed on the peeling layer 13 and the pattern layer 24 using Dainippon Ink Chemical Co., Ltd. Univia A, and the decorating sheet 5 containing a metallic gloss pattern was obtained (refer FIG. 5).

  The obtained decorative sheet 5 including a metallic gloss pattern is inserted into a molding die composed of an A die 31 and a B die 32, and the surface of the A die 31 and the pattern layer 24 forming surface of the first base sheet 20 are formed. It was fixed with the clamp 34 so that the surface on the opposite side contacted. After closing the molding die, the molding resin 38 was injected from the injection port 36 of the B die 32 (see FIG. 6). After cooling, the molding die is opened, the molding simultaneous decorative molded product 1 is taken out, the molding simultaneous decorative molded product 2 is taken out, and the first base sheet 20 is peeled and removed together with the release layer 21, so that it is simultaneously formed on the surface. The molding simultaneous decorative molded product 1 in which the decorative pattern 8 including the pattern layer 24 and the metal thin film layer 16 was formed could be obtained (see FIG. 7).

  Example 2 A metal thin film forming sheet was obtained in the same manner as in Example 1 except that a metal thin film layer made of copper having a thickness of 100 mm was formed by electroless plating. Subsequently, a decorative sheet was obtained in the same manner as in Example 1. Then, in the same manner as in Example 1, it was possible to obtain a molded simultaneous decorative molded product using a decorative sheet including a metallic gloss pattern.

  [Example 3] A metal thin film forming sheet was obtained in the same manner as in Example 1 except that a metal thin film layer made of tin having a thickness of 300 mm was formed by vacuum deposition in the production of the metal thin film forming sheet. Then, in the same manner as in Example 1, it was possible to obtain a molded simultaneous decorative molded product using a decorative sheet including a metallic gloss pattern.

  The metal having the same structure as Examples 1 to 3 except that each of the simultaneously molded decorative molded articles obtained in the above steps is Examples 1 to 3 and a conventional water washing step is performed when forming the metal thin film layer. The simultaneously molded decorative molded products obtained by the decorative sheet containing the glossy pattern were placed in a humidity resistance tester at 60 ° C. and 95 RH% as Comparative Examples 1 to 3, respectively, and allowed to stand for a certain period of time. It was evaluated with.

  The presence or absence of corrosion / rust on the metal thin film layer portion was evaluated by ○, Δ, and × by visual observation. ○: no corrosion / rust, Δ: slight corrosion / rust, x: corrosion / rust markedly visible. In addition, for the metal thin film layer part, incision lines with a spacing of 1 mm are drawn vertically and horizontally with a cutter knife so as to reach the resin of the molded product, and Nichibansello tape (registered trademark) is used for industrial purposes. Was peeled off immediately, and the peeled state of the grids was evaluated by ○, Δ, and ×. ○ indicates no peeling, Δ indicates peeling less than 50/100 of the grid, and x indicates peeling of 50/100 or more of the grid.

  The test results are as shown in Table 1, and for any of the molded simultaneous decorative molded products produced in Examples 1 to 3, the metal thin film layer was subjected to a process including a metallic gloss pattern that had undergone a conventional water washing process. It turned out that it is excellent compared with the shaping | molding simultaneous decorating molded product of each Comparative Examples 1-3 obtained with the decorating sheet.

  It is to be noted that, by appropriately combining any of the various embodiments, the effects possessed by them can be produced. Although the present invention has been fully described in connection with preferred embodiments with reference to the accompanying drawings, various variations and modifications will be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as long as they do not depart from the scope of the present invention.

It is sectional drawing which shows one Example of the metal thin film formation sheet used for manufacture of the decorating sheet containing the metallic luster pattern of this invention. It is sectional drawing which shows one Example of the decorating sheet of the stage which formed the pattern layer and position detection pattern which are used for manufacture of the decorating sheet containing the metallic luster pattern of this invention. It is sectional drawing which shows one Example of the step which added the heat with the thermal transfer printer from the back surface of a metal thin film formation sheet among the manufacturing methods of the decorating sheet | seat containing the metallic tone gloss pattern of this invention. It is sectional drawing which shows one Example of the decorating sheet of the stage in which the metal thin film layer etc. were formed on the pattern layer of the decorating sheet containing the metallic luster pattern of this invention. It is sectional drawing which shows one Example of the decorating sheet of the stage in which the contact bonding layer was formed in the metal thin film layer etc. of the decorating sheet containing the metallic luster pattern of this invention. It is sectional drawing which shows one Example of the manufacturing method of the simultaneous decoration decoration molded product of this invention. It is sectional drawing which shows one Example of the simultaneous decoration decoration molded product of this invention. It is a figure which shows the outline of the thermal transfer part of a general thermal transfer printer.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molding simultaneous decoration molded product 4 Decorating sheet containing a metallic luster pattern 5 Decorating sheet containing a metallic luster pattern 6 Metal thin forming sheet 8 Decorating pattern 9 Thermal transfer printer 10 Second base sheet 11, release layer 13 , Release layer 15 front anchor layer 16 metal thin film layer 19 rear anchor layer 20 first base sheet 21 mold release 23 release layer 24 picture layer 25 position detection pattern 29 adhesive layer 31 A mold 32 B mold 34 clamp 36 injection port 38 Molding resin 40 decorative sheet

Claims (5)

From the metal thin film forming sheet, a decorative sheet having a pattern layer formed on the first base sheet and a metal thin film forming sheet having a metal thin film layer formed on the second base sheet having releasability are laminated. A method of manufacturing a decorative sheet including a metallic gloss pattern in which the metal thin film layer is transferred and formed on the surface of the first base sheet on which the pattern layer is formed, wherein the transfer of the metal thin film layer is performed on demand. The manufacturing method of the decorating sheet | seat containing the metal-like glossy pattern characterized by being the printing system by. The method for producing a decorative sheet including a metallic gloss pattern according to claim 1, wherein the on-demand printing method is a thermal transfer printer method in which heat is applied from the back surface of the metal thin film forming sheet. A position detection pattern for pattern transfer forming the metal thin film layer from the metal thin film forming sheet to a predetermined position on the surface of the first base sheet on which the pattern layer is formed is provided before the transfer formation. The manufacturing method of the decorating sheet | seat containing the metallic luster pattern of Claim 1 or Claim 2 currently formed on the sheet | seat. The manufacturing method of the decorating sheet | seat containing the metallic luster pattern in any one of Claims 1-3 which formed the contact bonding layer as the uppermost layer after the transfer formation of the said metal thin film layer. The decorative sheet containing a metallic luster pattern obtained by the production method according to any one of claims 1 to 4 is inserted into a molding die composed of an A die and a B die, Molding in which a pattern layer and a metal thin film layer are formed on the surface at the same time as molding by fixing the first base sheet so that the surface on the opposite side to the pattern layer forming side is in contact with the molding die B A method for producing a simultaneously decorated and molded product, comprising obtaining a simultaneously decorated and molded product, and after cooling, removing the decorated and molded product from the mold.

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