JP2010247493A - Method of manufacturing in-mold decorative molded product, molded product manufactured thereby and decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing in-mold decorative molded products, a method that suppresses generation of gate flow and that thereby inhibits deterioration of designability in the in-mold decorative molded products. <P>SOLUTION: In the method of manufacturing in-mold decorative molded products, melted resin is injected into a mold through the gate of the mold, with a decorative sheet arranged in the mold having cavities, thereby closely sticking the decorative sheet to the surface of the resin molded product. The decorative sheet is composed of a substrate sheet and a plurality of layers containing layers that are laminated on the substrate sheet and that contain active energy beam curable resin. Before the injection of the melted resin, the planned gate-opposing region of the layers containing the resin is irradiated with the active energy beam, so that the planned gate-opposing region is preliminarily hardened. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for producing a molded simultaneous decorative molded product in which the surface of a resin molded product is decorated using a decorative sheet, the molded product, and a decorative sheet.

  2. Description of the Related Art Conventionally, as a method for decorating the surface of a resin molded product used for a mobile phone or a personal computer housing, a simultaneous molding method using a decorative sheet is known. The decorative sheet is a base sheet provided with a transfer layer composed of a release layer, a handle layer, an adhesive layer, and the like.

  At the same time as molding, the decorative sheet is sandwiched in the mold with the decorative sheet placed in the mold cavity, and after the molten resin is injected into the mold, it is cooled as appropriate to obtain a resin molded product. In this technique, a decorative sheet is bonded to the surface of the resin molded product, and then the base sheet is peeled off to decorate the surface of the resin molded product. This molding simultaneous decoration method has the feature that even if it is a resin molded product whose shape is difficult to form directly by the printing method, the design can be formed on the surface of the resin molded product. Yes. Here, a resin molded product decorated with a decorative sheet by the simultaneous molding method is referred to as a molded simultaneous decorative molded product.

  As an example of a conventional method for producing a simultaneously molded decorative product and a decorative sheet, there is one disclosed in Patent Document 1 (Japanese Patent Laid-Open No. 2005-186395), for example. Patent Document 1 discloses a semi-cured protective layer having ultraviolet curability on a base sheet, an ultraviolet absorbing layer, and ultraviolet curability for the purpose of preventing cracks from being formed in the simultaneously decorated decorative molded product. A method for producing a simultaneously molded decorative molded product using a decorative sheet obtained by sequentially laminating a cholesteric liquid crystal layer having the above is disclosed.

JP 2005-186395 A

  In the conventional method for producing a simultaneously decorated decorative molded product, when a molten resin is injected into a mold, a high temperature molten resin is generally injected at a high pressure. The surface of the adhesive layer is melted by the heat and pressure of the molten resin, and the transfer layer and the resin molded product are brought into close contact with each other.

  However, for example, when the thickness of the adhesive layer is too thick or the amount of the residual solvent contained in the adhesive layer is too large, the adhesive layer melted by the heat at the time of injection of the molten resin becomes a flow of the molten resin. As a result, there is a possibility that a part of the adjacent handle layer or peeling layer also flows at the same time. In this case, the designability of the simultaneously molded decorative molded product will be reduced. This problem occurs particularly in the vicinity of a mold gate that is a portion for injecting molten resin. This is usually due to the considerable difference between the mold temperature and the molten resin temperature. That is, the temperature of the molten resin injected from the gate of the mold is high in the vicinity of the gate, but shifts to a low temperature due to the influence of the temperature of the mold as the distance from the gate increases. For this reason, in the vicinity of the gate of the mold, the adhesive layer is melted too much, and part of the handle layer and the release layer is melted and easily flows. Hereinafter, it is referred to as “gate flow” that a part of the transfer layer excluding the adhesive layer melts and flows and the design property is impaired.

  Accordingly, an object of the present invention is to solve the above-described problem, and to produce a molded simultaneous decorative molded product that can suppress the generation of a gate flow and suppress the deterioration of the design of the molded simultaneous decorated molded product. It is in providing a method, its molded article, and a decorating sheet.

In order to achieve the above object, the present invention is configured as follows.
According to the first aspect of the present invention, in a state where a decorative sheet is disposed in a mold having a cavity, molten resin is injected into the mold through the gate of the mold, and is applied to the surface of the resin molded product. It is a method for producing a molded simultaneous decorative molded product that closely contacts the decorative sheet,
The decorative sheet includes a base sheet and a plurality of layers including a layer having an active energy ray-curable resin laminated on the base sheet.
Provided is a method for producing a molded simultaneous decorative molded product, in which, before injection of the molten resin, an active energy ray is irradiated to a region facing the gate of the layer having the resin and the region facing the gate is cured in advance. .
Here, the “gate-facing scheduled region” means a region facing the gate of the mold when the decorative sheet is placed in the mold in the layer having the active energy ray curable resin.

  According to the 2nd aspect of this invention, the layer which has the said resin provides the manufacturing method of the shaping | molding simultaneous decorating molded product as described in a 1st aspect currently formed in the whole surface of the said base sheet.

  According to the 3rd aspect of this invention, the layer which has the said resin is arrange | positioned inside the outer surface layer of the said decorating sheet, The manufacturing method of the shaping | molding simultaneous decoration molded product of the 1st or 2nd aspect I will provide a.

  According to the 4th aspect of this invention, the layer currently formed between the said outer surface layer of the said decorating sheet and the layer which has the said resin is transparent, The shaping | molding simultaneous decoration molded product of a 3rd aspect A manufacturing method is provided.

According to the fifth aspect of the present invention, the decorative sheet has a plurality of layers having the resin,
Any one of the first to fourth aspects, in which, before injection of the molten resin, active energy rays are applied to the gate-facing regions of the respective resin-containing layers, and the respective gate-facing regions are cured in advance. The manufacturing method of the simultaneous decoration decoration molded product as described in 1. is provided.

According to the sixth aspect of the present invention, the decorative sheet has at least a release layer and an adhesive layer,
The manufacturing method of the shaping | molding simultaneous decorating molded article as described in the 1st or 2nd aspect whose at least any one of the said peeling layer and the said contact bonding layer is a layer which has the said resin is provided.

According to the seventh aspect of the present invention, the decorative sheet has at least a release layer, a handle layer, and an adhesive layer,
Provided is a method for producing a molded simultaneous decorative molded product according to the first or second aspect, wherein at least one of the release layer, the handle layer, and the adhesive layer is a layer having the resin.

  According to the 8th aspect of this invention, the manufacturing method of the shaping | molding simultaneous decoration molded product as described in the 6th or 7th aspect whose said contact bonding layer is a layer which has the said resin is provided.

According to the ninth aspect of the present invention, the adhesive layer is a first adhesive layer disposed on the base sheet side, and the second adhesive layer is laminated on the first adhesive layer and becomes the outer surface layer of the decorative sheet. It consists of a multilayer structure with an adhesive layer,
The manufacturing method of the shaping | molding simultaneous decorating molded product of the 6th or 7th aspect whose said 2nd contact bonding layer is a layer which has the said resin is provided.

According to a tenth aspect of the present invention, the handle layer has a multi-layer structure having a first handle layer disposed on the base sheet side and a second handle layer laminated on the first handle layer. Configured,
The method for producing a simultaneously molded decorative molded product according to the seventh aspect, in which the second handle layer is a layer having the resin.

  According to an eleventh aspect of the present invention, the gate is simultaneously molded according to any one of the first to tenth aspects, wherein the gate is located at a position facing a flat portion of the molded simultaneous decorative molded product. A method for producing a decorative molded product is provided.

  According to a twelfth aspect of the present invention, the resin is an ultraviolet ray or electron beam curable resin, and the active energy ray is an ultraviolet ray or an electron beam. A method for manufacturing a product is provided.

According to the thirteenth aspect of the present invention, in a state where a decorative sheet is disposed in a mold having a cavity, molten resin is injected into the mold through the gate of the mold, and is applied to the surface of the resin molded product. A decorative sheet used in a method for producing a molded simultaneous decorative molded product in close contact with the decorative sheet,
The decorative sheet includes a base sheet and a plurality of layers including a layer having an active energy ray-curable resin laminated on the base sheet, and only a gate facing scheduled region of the layer including the resin is cured. Provide a decorative sheet.

  According to the fourteenth aspect of the present invention, there is provided a molded simultaneous decorative molded product whose surface is decorated with the decorative sheet according to the thirteenth aspect.

  According to the method for producing a simultaneously molded decorative molded product of the present invention, the gate facing planned region of the decorative sheet is cured in advance before the injection of the molten resin, so that the generation of the gate flow is suppressed. Thus, it is possible to suppress a decrease in the designability of the simultaneously molded decorative molded product.

  In addition, the gate flow can be achieved by another method such as reducing the amount of residual solvent contained in the adhesive layer or the pattern layer by increasing the drying condition of the decorative sheet, or reducing the coating amount of the adhesive layer. It is possible to suppress it. However, in this case, the decorative sheet may cause poor adhesion to the resin molded product, particularly in the outer peripheral portion of the resin molded product that is difficult to apply the heat and pressure of the molten resin. Moreover, a gate flow can also be suppressed by providing the layer which has a thermosetting resin in a decorating sheet, and thermosetting the gate opposing plan area | region of the said layer, for example. However, when the layer having the thermosetting resin is thermally cured, irregularities are formed on the surface of the cured portion. For this reason, when only a part of the layer having the thermosetting resin is cured, the boundary between the portion having the unevenness and the portion having no unevenness is visually recognized even when the layer is made of a transparent member. Cannot be concealed and may adversely affect the design. On the other hand, when the entire layer having the thermosetting resin is cured, it is possible to suppress a decrease in designability, but particularly in the outer peripheral portion of the resin molded product that is difficult to apply heat and pressure of the molten resin. May cause failure. In addition, when the entire layer having a thermosetting resin is cured, the flexibility of the decorative sheet is impaired, so when there is a portion with a large curvature in the molded simultaneous decorative molded product, Cracks are likely to occur. In addition, when a layer having a thermosetting resin is provided on the entire decorative sheet and cured, the pattern layer of the decorative sheet is increased in strength, so that the pattern layer is difficult to cut at the parting line of the injection molded product, and the foil Is likely to occur.

  On the other hand, according to the method for producing a simultaneously decorated decorative molded product of the present invention, without reducing the amount of residual solvent contained in the adhesive layer and the pattern layer, and without reducing the coating amount of the adhesive layer. Since the generation of the gate flow can be suppressed, the problem of the adhesion failure can be solved. Further, since the generation of the gate flow is suppressed without using a thermosetting resin, the crack problem can be solved.

  According to the decorative sheet of the present invention, since only the gate facing planned region of the layer comprising the resin is cured, the generation of the gate flow of the molded simultaneous decorative molded product is suppressed, and the molded simultaneous decorative molded product A decrease in design properties can be suppressed.

It is sectional drawing of the decorating sheet used for the manufacturing method of the shaping | molding simultaneous decorating molded product concerning embodiment of this invention. It is sectional drawing which shows a mode that an active energy ray is irradiated to a part of decorating sheet | seat of FIG. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 1 hardened | cured. It is a side view which shows schematic structure of the simultaneous shaping | molding decoration apparatus used for the manufacturing method of the shaping | molding simultaneous decoration molded product concerning embodiment of this invention. It is sectional drawing of the shaping | molding simultaneous decoration molded product manufactured by the manufacturing method of the molding simultaneous decoration molded product concerning embodiment of this invention. It is sectional drawing which shows the 1st modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 6A hardened. It is sectional drawing which shows the 2nd modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 7A hardened | cured. It is sectional drawing which shows the 3rd modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 8A hardened | cured. It is sectional drawing which shows the 4-6th modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 9A hardened | cured. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 9A hardened | cured. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 9A hardened | cured. It is sectional drawing which shows the 7th modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 10A hardened | cured. It is sectional drawing which shows the 8th modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 11A hardened | cured. It is sectional drawing which shows the 9th modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 12A hardened | cured. It is sectional drawing which shows the 10-12th modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 13A hardened | cured. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 13A hardened | cured. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 13A hardened | cured. It is sectional drawing which shows the 13-15th modification of a decorating sheet. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 14A hardened | cured. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 14A hardened | cured. It is sectional drawing which shows the state which a part of decorating sheet of FIG. 14A hardened | cured.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

<Embodiment>
FIG. 1 is a cross-sectional view of a decorative sheet used in a method for producing a simultaneously molded decorative molded product according to an embodiment of the present invention.

  In FIG. 1, the decorative sheet 1 includes a base sheet 11 and a transfer layer 12 laminated on the base sheet 11. The transfer layer 12 includes a release layer 13 stacked on the base sheet 11, a handle layer 14 stacked on the release layer 13, and an adhesive layer 15 f stacked on the handle layer 14. As will be described in detail later, the adhesive layer 15f is configured to have an ultraviolet ray or electron beam curable resin which is an example of an active energy ray curable resin. Note that in this specification, in order to distinguish between a layer having ultraviolet or electron beam curable resin and a layer not containing the resin, the layer having the resin is labeled with “f”.

  The base sheet 11 is a sheet that supports the transfer layer 12. Examples of the base sheet 11 include resin sheets such as polypropylene resin, polystyrene resin, polyamide resin, polyester resin, acrylic resin, and polyvinyl chloride resin, metal foil such as aluminum foil and copper foil, and glassine paper. Cellulose-based sheets such as coated paper and cellophane, or a composite sheet of these can be used.

  The release layer 13 is a layer for peeling the base sheet 11 from the transfer layer 12. The release layer 13 is a layer that becomes the outermost surface when the base sheet 11 is peeled from the transfer layer 12, that is, a layer that becomes the outer surface of the simultaneously molded decorative molded product. For this reason, it is preferable that the peeling layer 13 has a hard coat function.

  Examples of the material of the release layer 13 include acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, and vinyl chloride-vinyl acetate. Copolymers such as ethylene-based copolymer resins and ethylene-vinyl acetate copolymer resins can be used. When the release layer 13 requires hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, a thermosetting resin, or the like may be selected and used.

  As a method for forming the release layer 13, for example, a coating method such as a gravure coating method, a roll coating method, or a comma coating method, a printing method such as a gravure printing method, or a screen printing method can be used.

The pattern layer 14 is a layer for expressing a pattern or the like, and is usually formed on the release layer 13 as a printing layer.
As a material for the pattern layer 14, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, or an alkyd resin is used as a binder. And a color ink containing a pigment or dye of an appropriate color as a colorant can be used.

  As a method for forming the pattern layer 14, a normal printing method such as a gravure printing method, a screen printing method, or an offset printing method can be used. In the pattern layer 14, an offset printing method and a gravure printing method are suitable for performing multicolor printing and gradation expression. When the pattern layer is a single color, a coating method such as a gravure coating method, a roll coating method, or a comma coating method may be used.

  The adhesive layer 15f is a layer for adhering the transfer layer 12 and a resin molded product as a decoration object. As the material of the adhesive layer 15f, a heat-sensitive or pressure-sensitive resin suitable for the material of the resin molded product can be used as appropriate. For example, when the material of the resin molded product is an acrylic resin, an acrylic resin may be used. In addition, when the material of the resin molded product is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, A polyamide resin or the like may be used. Further, when the material of the resin molded product is a polypropylene resin, a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a cyclized rubber, or a coumarone indene resin may be used.

  As a method for forming the adhesive layer 15f, a coating method such as a gravure coating method, a roll coating method, or a comma coating method, a printing method such as a gravure printing method, or a screen printing method can be used.

  In the present embodiment, the adhesive layer 15f is a layer for preventing gate flow. For this reason, the adhesive layer 15f is configured to have ultraviolet rays or an electron beam curable resin. Specifically, the adhesive layer 15f is configured by mixing ultraviolet or electron beam curable resin with the heat-sensitive or pressure-sensitive resin. Note that the adhesive layer 15f may be formed of a single resin having both ultraviolet ray or electron beam curability and heat or pressure sensitive properties. Thereby, as shown in FIG. 2, the adhesive layer 15f is irradiated with ultraviolet rays (UV) or electron beams (EB), which are examples of active energy rays, from the active energy ray irradiator 2, as shown in FIG. Thus, the irradiated region 15c is configured to be cured. In this embodiment, the region of the adhesive layer 15f that irradiates ultraviolet rays is a region facing the gate of the mold when the decorative sheet 1 is placed in the mold, as will be described in detail later. This is a planned area.

  Examples of the ultraviolet or electron beam curable resins include acrylate compounds or derivatives, unsaturated polyester compounds or derivatives, radical curable resins such as ene / thiol compounds or derivatives, epoxy compounds or derivatives, vinyl ether compounds or derivatives. Cationic curable resins such as oxetane compounds or derivatives can be used.

  The ultraviolet or electron beam curable resin is preferably applied to the entire surface of the adhesive layer 15f. Thereby, it can suppress that the nonuniformity by the variation of the said resin arises in the design of a shaping | molding simultaneous decorating molded product.

  Next, the simultaneous molding decoration device used for the manufacturing method of the simultaneous molding decorative molded product according to the embodiment of the present invention will be described with reference to FIG. FIG. 4: is a side view which shows schematic structure of the shaping | molding simultaneous decoration apparatus used for the manufacturing method of the shaping | molding simultaneous decoration molded product concerning embodiment of this invention. In addition, the shaping | molding simultaneous decoration apparatus used for the manufacturing method of a shaping | molding simultaneous decoration molded product is not limited to this structure, Other known simultaneous shaping | molding decoration apparatuses may be sufficient.

The simultaneous molding decoration device shown in FIG. 4 includes a mold 20, an injection molding machine 30, and a decorative sheet supply device 40.
The mold 20 includes a movable mold 21 having a concave cavity 21A and a fixed mold 22 having a concave cavity 22A.

  The injection molding machine 30 includes a fixed platen 31 that supports the fixed mold 22, a movable platen 32 that supports the movable mold 21, and a platen surface (fixed mold support surface) of the fixed platen 31 that slides on the movable platen 32. And a plurality of tie bars 33 penetrating therethrough. The injection molding machine 30 can close the fixed mold 22 and the movable mold 21 by sliding the movable platen 32 toward the fixed platen 31 on the tie bar 33. Further, the injection molding machine 30 is provided with molten resin in the fixed mold 22 using an injection nozzle 34 in a cavity space formed by the cavity 21A of the movable mold 21 and the cavity 22A of the fixed mold 22 in the mold closed state. The resin molded product 16 can be molded by being injected from the gate 35. The gate 35 may have an arbitrary shape such as a circle, an ellipse, or a slit.

  The decorative sheet supply device 40 is a device that supplies the decorative sheet 1 between the movable mold 21 and the fixed mold 22. The decorative sheet supply device 40 includes a decorative sheet delivery device 41 and a decorative sheet take-up device 46.

  The decorating sheet sending device 41 includes a decorating sheet sending roll 42 having a rotating shaft around which the long decor sheet 1 is wound, a guide roller 43, a frame 44, and a fixing portion 45. The decorating sheet sending device 41 sends out the decorating sheet 1 by rotating the decorating sheet sending roll 42, and the sent decorating sheet 1 is placed between the movable mold 21 and the fixed mold 22 by the guide roller 43. Move towards. The decorating sheet delivery roll 42 and the guide roller 43 are arranged in parallel to each other, and are rotatably supported by the frame 44. A fixed portion 45 is attached to the frame 44 in a direction parallel to the rotation axis of the guide roller 43 and perpendicular to the surface of the frame 44. The fixing portion 45 is fixed to the platen surface by a fastening member such as a bolt so as to be parallel to the platen surface (movable support surface) of the movable platen 32.

  The decorative sheet take-up device 46 peels the transfer sheet 12 from the transfer layer 12 and passes between the movable mold 21 and the fixed mold 22 to the decorative sheet take-up roll 47 by the guide roller 48. The base sheet 11 is wound up by moving and rotating the decorative sheet winding roll 47. The decorative sheet take-up roll 47 and the guide roller 48 are arranged in parallel with the decorative sheet feed roll 42 and the guide roller 43, and are rotatably supported by the frame 49. A plate-shaped fixing portion 50 is attached to the frame 49 in a direction parallel to the rotation axis of the guide roller 48 and perpendicular to the surface of the frame 49. The fixing portion 50 is fixed to the platen surface with a fastening member such as a bolt so as to be parallel to the platen surface of the movable platen 32.

  Next, a method for manufacturing a simultaneously molded decorative molded product according to an embodiment of the present invention will be described with reference to FIGS. FIG. 5 is a cross-sectional view of a simultaneously molded decorative molded product according to an embodiment of the present invention.

  First, as shown in FIG. 4, the decorative sheet 1 is set between the decorative sheet sending roll 42 and the decorative sheet winding roll 47. Here, although the decorative sheet 1 in which the gate facing region 15c of the adhesive layer 15f is cured in advance is set on the decorative sheet delivery roll 42, the present invention is not limited to this. It is only necessary that the gate-facing planned region 15c be cured before the gate-facing planned region 15c is disposed in the mold 20 and the molten resin is injected into the mold 20 that is closed. For example, the active energy ray irradiator 2 is disposed between the guide roller 43 and the movable die 21, and the gate facing planned region 15 c is cured by irradiating the gate facing planned region 15 c with the ultraviolet or electron beam from the irradiator 2. You may make it make it.

  Next, the decorating sheet 1 is sent out from the decorating sheet delivery roll 42, and the gate facing area 15 c is positioned at a position facing the gate 35. In general, the decorative sheet is provided with an alignment mark for pattern matching with the resin molded product. The positional relationship among the alignment mark, the pattern on the pattern layer, and the gate facing planned area is always constant. Therefore, by recognizing the position of the alignment mark with a camera or the like, the position of the gate facing scheduled area can be known. Based on this recognition result, by controlling the decorative sheet delivery amount of the decorative sheet delivery roll 42 (or the decorative sheet take-up amount of the decorative sheet take-up roll 47), the gate facing scheduled area and the gate 35 are controlled. Positioning can be performed accurately. In addition, when the alignment mark for pattern alignment is not provided to the decorating sheet, the alignment mark may be provided at a position on the decorating sheet 1 that is a certain distance away from the gate facing scheduled region 15c. . In this case, the positioning mark is recognized by a separately provided camera or the like, and the decorative sheet feed amount of the decorative sheet feed roll 42 (or the decorative sheet take-up roll of the decorative sheet take-up roll 47 is based on the recognition result. By controlling (amount), it is possible to accurately align the gate facing scheduled region and the gate 35.

Next, the movable mold 21 and the fixed mold 22 are closed with the decorative sheet 1 disposed between the movable mold 21 and the fixed mold 22.
Next, molten resin is injected from the gate 35 into the cavity space formed by the cavity 21 </ b> A and the cavity 22 </ b> A using the injection nozzle 34. Thereby, as shown in FIG. 5, the resin molded product 16 is molded, and the decorative sheet 1 is in close contact with the surface of the resin molded product 16. At this time, the gate-facing region 15c of the adhesive layer 15f is cured in advance, so that the adhesive layer 15f is not excessively melted. Therefore, the gate flow is suppressed. Further, since the region other than the gate-facing region 15c of the adhesive layer 15f is not cured, the occurrence of cracks and poor adhesion due to the adhesive layer 15f being too hard can be suppressed. Note that the adhesive layer 15f is a single resin having ultraviolet or electron beam curable resin mixed with the heat-sensitive or pressure-sensitive resin (or an ultraviolet or electron beam-curable, heat-sensitive or pressure-sensitive property). Therefore, the gate-facing scheduled region 15c has an adhesive force even after curing. For this reason, the occurrence of poor adhesion can be suppressed even in the gate facing scheduled region 15c. In addition, although the adhesive force after hardening of the gate opposing plan area | region 15c of the contact bonding layer 15f becomes weaker than before hardening, since the heat and pressure of molten resin are fully applied in a gate part, the gate opposing planned area | region 15c of the contact bonding layer 15f Adheres to the resin molded product 16 without any problem.

  After the resin molded product 16 is appropriately cooled and the resin molded product 16 is cured, the mold closed state of the movable mold 21 and the fixed mold 22 is released. As a result, the base sheet 11 is peeled off from the transfer layer 12 leaving the transfer layer 12 on the surface of the resin molded product, and the simultaneously molded decorative molded product 3 as shown in FIG. 5 is manufactured. The peeled base sheet 11 is taken up by the decorative sheet take-up roll 47.

  As described above, according to the method for manufacturing a simultaneously decorated decorative molded product according to the embodiment of the present invention, the gate facing scheduled region 15c of the adhesive layer 15f is cured in advance before injection of the molten resin. Generation | occurrence | production of can be suppressed and the fall of the designability of the simultaneous decoration decoration molded product 3 can be suppressed. Further, since the region other than the gate facing planned region 15c of the adhesive layer 15f is not cured, the occurrence of cracks and poor adhesion due to the adhesive layer 15f being too hard can be suppressed.

  As shown in FIG. 5, the gate facing planned region 15 c is preferably located at a position corresponding to a flat portion of the resin molded product 16 rather than a curved surface portion of the resin molded product 16. As a result, there is no possibility of cracks occurring in the hardened gate facing scheduled region 15c.

  In addition, this invention is not limited to the said embodiment, It can implement in another various aspect. For example, in the said embodiment, although the decorating sheet was comprised so that an adhesive layer might have an ultraviolet-ray or electron beam curable resin, this invention is not limited to this. Since the layer having the ultraviolet ray or electron beam curable resin has a sticky property, the presence of the layer having the ultraviolet ray or electron beam curable resin on the outer surface layer of the decorative sheet 1 deteriorates the handleability of the layer. This is not preferable because blocking that partly peels off may occur.

(First modification of decorative sheet)
For this reason, as shown to FIG. 6A, you may comprise a decorating sheet so that the pattern layer 14f may have an ultraviolet-ray or electron beam curable resin instead of the contact bonding layer 15. FIG. Thereby, while being able to suppress the gate flow of the pattern layer 14f and the peeling layer 13, the handleability of a decorating sheet can be improved and generation | occurrence | production of blocking can also be suppressed. In this case, it is the gate facing scheduled region 14c shown in FIG. 6B that is cured by irradiation with ultraviolet rays or electron beams.

(Second modification of decorative sheet)
Moreover, as shown to FIG. 7A, you may comprise a decorating sheet so that the peeling layer 13f may have an ultraviolet-ray or electron beam curable resin. Thereby, while being able to suppress the gate flow of peeling layer 13f, the handleability of a decorating sheet can be improved and generation | occurrence | production of blocking can also be suppressed. In this case, it is the gate facing scheduled region 13c shown in FIG. 7B that is cured by irradiation with ultraviolet rays or electron beams.

In the above configuration, when the gate flow occurs in the handle layer 14 due to the low heat resistance of the handle layer 14, the generation of the gate flow is prevented even if the gate-facing region 13c of the release layer 13f is cured. Can not. On the other hand, when the decorative sheet is configured so that the pattern layer 14 or the adhesive layer 15f has an ultraviolet ray or an electron beam curable resin, generation of a gate flow can be prevented. That is, in the transfer layer 12, it is preferable that the layer located on the outermost side (the side away from the base sheet 11) among the layers that may cause a gate flow contains an ultraviolet ray or an electron beam curable resin.
Moreover, it is preferable that the layer arrange | positioned between the outer surface layer of the decorating sheet 1 and the layer which has an ultraviolet-ray or electron beam curable resin is transparent. When the layer is not transparent (for example, when it is a metal thin film layer to be described later), there is a possibility that the path of ultraviolet rays or electron beams is blocked by the layer and does not reach the layer having ultraviolet rays or electron beam curable resin.

(Third modification of decorative sheet)
Moreover, although the said embodiment demonstrated the decorating sheet | seat in which an ultraviolet-ray or electron beam curable resin was contained only in 1 layer, as shown to FIG. 8A, an ultraviolet-ray or electron beam curable resin is contained in two or more layers. May be. FIG. 8A shows an example of a decorative sheet in which ultraviolet rays or an electron beam curable resin is included in two layers of the handle layer 14f and the adhesive layer 15f. In this case, it is the gate-facing regions 14c and 15c shown in FIG. 8B that are cured by irradiation with ultraviolet rays or electron beams.

(4-6th modification of decorative sheet)
Moreover, in the said embodiment, although the transfer layer shall be comprised by three layers, the peeling layer 13, the pattern layer 14, and the contact bonding layer 15, this invention is not limited to this. Since the gate flow is generated not only in the handle layer 14 but also in the release layer 13, the transfer layer 12 may be composed of two layers of the release layer 13 and the adhesive layer 15, for example, as shown in FIG. 9A. In this case, the ultraviolet ray or the electron beam curable resin may be contained in at least one of the peeling layer 13 and the adhesive layer 15. When ultraviolet ray or electron beam curable resin is included in the adhesive layer 15f (fourth modified example), it is the gate facing scheduled region 15c shown in FIG. 9B that is cured by irradiation with ultraviolet ray or electron beam. When ultraviolet rays or an electron beam curable resin is included in the release layer 13f (fifth modified example), it is the gate facing scheduled region 13c shown in FIG. 9C that is cured by irradiation with ultraviolet rays or an electron beam. When ultraviolet rays or an electron beam curable resin is included in two layers of the peeling layer 13f and the adhesive layer 15f (sixth modified example), the region opposite to the gate shown in FIG. 9D is cured by irradiation with ultraviolet rays or an electron beam. 13c and 15c.

(Seventh modification of the decorative sheet)
Moreover, in the above, although the decorating sheet was comprised so that any layer of the peeling layer 13, the handle layer 14, and the contact bonding layer 15 might have an ultraviolet-ray or an electron beam curable resin, this invention is not limited to this. For example, as shown in FIG. 10A, a release layer 17f is provided between the base sheet 11 and the release layer 13, and the decorative sheet is configured so that the release layer 17f has ultraviolet or electron beam curable resin. May be. The release layer 17 f is a layer for improving the peelability of the release layer 13 from the base sheet 11. In this case, the region facing the gate facing region 17c shown in FIG. 10B is cured by irradiation with ultraviolet rays or electron beams.

  As a material of the release layer 17, melamine resin release agent, silicone resin release agent, fluororesin release agent, cellulose derivative release agent, urea resin release agent, polyolefin resin release agent , Paraffin-based mold release agents, composite mold release agents, and the like can be used. As a method for forming the release layer, a coating method such as a roll coating method or a spray coating method, a gravure printing method, a screen printing method, or the like can be used.

(Eighth modified example of the decorative sheet)
Moreover, as shown to FIG. 11A, even if an anchor layer 18f is provided between the handle layer 14 and the contact bonding layer 15, and a decoration sheet | seat is comprised so that the said anchor layer 18f may have an ultraviolet-ray or electron beam curable resin, Good. The anchor layer 18f is a layer for improving the adhesion between adjacent layers. In this case, it is the gate-facing region 18c shown in FIG. 11B that is cured by being irradiated with ultraviolet rays or electron beams. The anchor layer 18 f may be provided between the base sheet 11 and the release layer 17 or between the release layer 13 and the handle layer 14.

  As the material of the anchor layer 18, two-component cured urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, acrylic resin, epoxy resin, vinyl A copolymer resin or the like can be used.

  As the formation method of the anchor layer 18, a gravure coating method, a roll coating method, a coating method such as a comma coating method, a printing method such as a gravure printing method, a screen printing method, or the like can be used.

(Ninth modification of decorative sheet)
Also, as shown in FIG. 12A, a metal thin film layer 19f is provided between the handle layer 14 and the adhesive layer 15, and the decorative sheet is configured so that the metal thin film layer 19f has ultraviolet rays or an electron beam curable resin. May be. The metal thin film layer 19f is a layer for giving the handle layer 14 a metallic luster. In this case, the region opposite to the gate facing region 19c shown in FIG. 12B is cured by irradiation with ultraviolet rays or electron beams. Note that the metal thin film layer 19 f may be provided between the release layer 13 and the handle layer 14.

  As the material of the metal thin film layer 19, metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, and zinc, and alloys or compounds thereof can be used. What is necessary is just to select the material of the metal thin film layer 19 suitably according to the metallic luster color to express. As a method for forming the metal thin film layer 19, a method such as a vacuum deposition method, a sputtering method, an ion plating method, or a plating method can be used.

(10th-12th modification of a decoration sheet)
Moreover, in the said 1st Embodiment, although the contact bonding layer 15 was made into the single layer, this invention is not limited to this, A multilayer structure may be sufficient. FIG. 13A shows an example in which the adhesive layer 15 has a two-layer structure of a first adhesive layer 15A and a second adhesive layer 15B. The ultraviolet or electron beam curable resin may be contained in at least one of the first adhesive layer 15A and the second adhesive layer 15B. When ultraviolet rays or an electron beam curable resin is included in the first adhesive layer 15Af (the tenth modification), it is the gate facing scheduled region 15Ac shown in FIG. 13B that is cured by irradiation with ultraviolet rays or an electron beam. In this case, the gate flow of the handle layer 14f and the release layer 13 can be suppressed, the handleability of the decorative sheet can be improved, and the occurrence of blocking can also be suppressed. When ultraviolet rays or an electron beam curable resin is contained in the first adhesive layer 15Bf (an eleventh modified example), it is the gate-facing region 15Bc shown in FIG. 13C that is cured by irradiation with ultraviolet rays or an electron beam. When ultraviolet rays or an electron beam curable resin is contained in the first adhesive layer 15Af and the second adhesive layer 15Bf (a twelfth modified example), curing by irradiation with ultraviolet rays or an electron beam is scheduled to face the gate shown in FIG. 13D. Regions 15Ac and 15Bc.

(13-15th modification of a decoration sheet)
Further, as shown in FIG. 14A, the pattern layer 14 has a two-layer structure of a first pattern layer 14A and a second pattern layer 14B. The ultraviolet or electron beam curable resin may be contained in at least one of the first handle layer 14A and the second handle layer 14B.

  When ultraviolet rays or an electron beam curable resin is included in the first handle layer 14Af (a thirteenth modified example), it is the gate facing scheduled region 14Ac shown in FIG. 14B that is cured by irradiation with ultraviolet rays or an electron beam. In this case, although the gate flow of the first pattern layer 14A can be suppressed, the gate flow of the second pattern layer 14B may not be suppressed. Accordingly, there may be a case where a decrease in designability of the simultaneously molded decorative molded product cannot be suppressed.

  When ultraviolet rays or an electron beam curable resin is contained in the first handle layer 14Bf (fourteenth modified example), the region facing the gate facing region 14Bc shown in FIG. 14C is cured by irradiation with ultraviolet rays or an electron beam. In this case, since the gate facing scheduled region 14Bc of the second pattern layer 14B is cured, the gate flow of the first pattern layer 14A is suppressed, so that the design of the simultaneously molded decorative molded product can be prevented from being deteriorated.

  When ultraviolet rays or an electron beam curable resin is contained in the first handle layer 14Af and the second handle layer 14Bf (fifteenth modified example), curing by irradiation with ultraviolet rays or an electron beam is scheduled to face the gate shown in FIG. 13D. Regions 14Ac and 14Bc.

  In addition, it can be made to show each effect which it has by combining suitably arbitrary embodiment among the said various embodiment (modification).

  Since the method for producing a molded simultaneous decorative molded product according to the present invention and the molded product thereof, and the decorative sheet can suppress the generation of the gate flow and can suppress the deterioration of the design of the molded simultaneous decorative molded product, This is useful for decorating resin molded products such as mobile phones and personal computer housings.

DESCRIPTION OF SYMBOLS 1 Decorative sheet 2 Active energy ray irradiation machine 3 Molding simultaneous decoration molded product 11 Base sheet 12 Transfer layer 13 Peeling layer 14 Handle layer 15 Adhesive layer 16 Resin molded product 17 Release layer 18 Anchor layer 19 Metal thin film layer

Claims (14)

With the decorative sheet placed in a mold having a cavity, molten resin is injected into the mold through the gate of the mold, and simultaneous molding is performed so that the decorative sheet is in close contact with the surface of the resin molded product. A method for producing a decorative molded article,
The decorative sheet includes a base sheet and a plurality of layers including a layer having an active energy ray-curable resin laminated on the base sheet.
Before injection of the molten resin, a method for producing a molded simultaneous decorative molded product, in which the region facing the gate of the layer having the resin is irradiated with active energy rays and the region facing the gate facing is cured in advance.   The method for producing a molded simultaneous decorative molded product according to claim 1, wherein the resin-containing layer is formed on the entire surface of the base sheet.   The layer having the resin is a method for producing a molded simultaneous decorative molded product according to claim 1 or 2, wherein the layer having the resin is disposed on the inner side of the outer surface layer of the decorative sheet.   The method for producing a simultaneously molded decorative molded product according to claim 3, wherein a layer formed between the outer surface layer of the decorative sheet and the layer having the resin is transparent. The decorative sheet has a plurality of layers having the resin,
Before injection of the molten resin, active energy rays are irradiated to the gate facing regions of the respective resin-containing layers, and the respective gate facing regions are cured in advance. The manufacturing method of the simultaneously decorated decorative molded product described in 1. The decorative sheet has at least a release layer and an adhesive layer,
The method for producing a simultaneously molded decorative molded product according to claim 1 or 2, wherein at least one of the release layer and the adhesive layer is a layer having the resin. The decorative sheet has at least a release layer, a handle layer, and an adhesive layer,
The method for producing a molded simultaneous decorative molded product according to claim 1, wherein at least one of the release layer, the handle layer, and the adhesive layer is a layer having the resin.   The method for producing a molded simultaneous decorative molded product according to claim 6 or 7, wherein the adhesive layer is a layer having the resin. The adhesive layer has a multilayer structure including a first adhesive layer disposed on the base sheet side and a second adhesive layer laminated on the first adhesive layer and serving as an outer surface layer of the decorative sheet. And
The method for producing a molded simultaneous decorative molded product according to claim 6 or 7, wherein the second adhesive layer is a layer containing the resin. The handle layer is composed of a multilayer structure having a first handle layer disposed on the base sheet side and a second handle layer laminated on the first handle layer,
The method for producing a molded simultaneous decorative molded product according to claim 7, wherein the second handle layer is a layer having the resin.   The said gate is a manufacturing method of the shaping | molding simultaneous decoration molded product of any one of Claims 1-10 located in the position facing the flat part of the said shaping | molding simultaneous decoration molded product.   The method for producing a molded simultaneous decorative molded product according to claim 1, wherein the resin is an ultraviolet ray or an electron beam curable resin, and the active energy ray is an ultraviolet ray or an electron beam. With the decorative sheet placed in a mold having a cavity, molten resin is injected into the mold through the gate of the mold, and simultaneous molding is performed so that the decorative sheet is in close contact with the surface of the resin molded product. A decorative sheet used in a method for producing a decorative molded article,
The decorative sheet includes a base sheet and a plurality of layers including a layer having an active energy ray-curable resin laminated on the base sheet, and only a gate facing scheduled region of the layer including the resin is cured. A decorative sheet.   The molding simultaneous decoration molded product by which the surface was decorated by the decorating sheet of Claim 13.

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