JP2011207133A - Optical reflecting film for insert molding, and method for manufacturing insert-molded article using the same - Google Patents

Optical reflecting film for insert molding, and method for manufacturing insert-molded article using the same Download PDF

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JP2011207133A
JP2011207133A JP2010078576A JP2010078576A JP2011207133A JP 2011207133 A JP2011207133 A JP 2011207133A JP 2010078576 A JP2010078576 A JP 2010078576A JP 2010078576 A JP2010078576 A JP 2010078576A JP 2011207133 A JP2011207133 A JP 2011207133A
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film
optical
layer
optical reflective
insert molding
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JP5640428B2 (en
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Koichiro Kanayama
浩一郎 金山
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Toppan Printing Co Ltd
凸版印刷株式会社
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Abstract

Kind Code: A1 The present invention relates to an optical reflection film having a deterrent effect on the occurrence of cracks in an optical reflection layer related to a decoration performance in insert molding using an optical reflection film responsible for surface decoration with a metallic surface gloss. Provided is a manufacturing method that realizes a molded article with high designability by using this for injection molding by a film insert method.
The structure of the optical reflective film for insert molding is as follows. An optical reflection layer made of one or more metal films or metal compound films and having a thickness of 200 nm or more and 400 nm or less is formed on one surface of a substrate made of a plastic film. On the optical reflection layer, a colored layer is formed for the purpose of improving the glitter and the heat absorption.
[Selection] Figure 1

Description

  The present invention relates to surface decoration of plastics such as electric devices such as telephones and personal computers and cosmetic containers. In particular, the present invention relates to an optical reflective film having a metallic luster to be used for a film insert method and a structure of an insert molded product as a decorative molded product, and a manufacturing method.

In recent years, surface decoration of plastic molded products has been required to be highly expressive.
In general, as surface decoration of plastic molded products, methods such as direct printing, transfer printing, foil stamping, painting, underwater transfer, etc. are used to decorate plastic molded products after molding, in-mold molding methods There is also a method of decorating at the same time as molding, using simultaneous painting with injection molding by the insert molding method or the like. By these decoration methods, it is possible to express by decoration using a wide variety of patterns such as abstract paintings, photographs, woodgrains, designs, and gradations.

  However, as a method for obtaining a product having a glossiness of a metal surface tone, as described in Patent Document 1, a method of directly metal plating on the surface of a plastic molded product has been mainstream.

JP 2007-190702 A

  Usually, since the plating film of metal plating is a thick film of 0.5 to 1 mm, the flexibility which is a characteristic of the resin is completely obscured, resulting in a product with poor shock absorption. In addition, to protect the plating film, the overcoat material must be clear painted after plating, and when colored, another colored coating is required after plating, which increases the number of processes and increases costs. Big and poor productivity. In addition, since waste liquid treatment for plating and painting is required, it is necessary to take measures against deterioration of the working environment.

  On the other hand, in an optical reflective film in which an optical reflective layer is formed of a metal film, the optical reflective layer may be stretched by a process such as molding to cause cracks. In the case where a crack occurs, in the surface decoration of a plastic molded product in which an optical reflection layer is formed by a metal film, a decrease in design property tends to be a problem.

  The present invention has been made paying attention to the above points, and in an insert molding using an optical reflective film responsible for surface decoration having a metallic surface gloss, an optical reflective layer related to the decoration performance is provided. To provide a manufacturing method that can obtain a molded article with high designability by realizing a configuration of an optical reflection film having an effect of suppressing crack generation and using it for injection molding by a film insert method. With the goal.

  In order to solve the above-mentioned problems, the invention described in claim 1 of the present invention is formed of one or more metal films or metal compound films on one surface of a substrate made of a plastic film and has a thickness of 200 nm to 400 nm. Provided is an optical reflective film for insert molding, characterized in that the following optical reflective layer is formed, and a colored layer is formed on the optical reflective layer for the purpose of improving luster and heat absorption. Is.

Next, the invention described in claim 2 is characterized in that the residual internal stress of the optical reflecting layer is −300 MPa or more with respect to the structure described in claim 1.
Next, the invention described in claim 3 is characterized in that a hard coat layer is formed on the other surface of the base material with respect to the configuration described in claim 1 or claim 2. is there.
Next, in the invention described in claim 4, a buffer layer is interposed between the base material and the optical reflective layer in the configuration described in any one of claims 1 to 3. It is characterized by.

  Next, in the invention described in claim 5, in the configuration described in any one of claims 1 to 4, the optical reflective layer has a laminated structure of two or more layers. At least two layers are each composed of a high refractive material and a low refractive material.

  Next, in the invention described in claim 6, the optical reflective film for insert molding according to any one of claims 1 to 5 is placed in an injection mold, and heated and vacuumed. After processing into a three-dimensional shape with a large difference in unevenness, the optical reflective film for insert molding is brought into close contact with the cavity forming surface of the injection mold, and then the mold is clamped to form a molding resin in the cavity in the mold. The method of manufacturing an insert molded product is characterized in that the optical reflective film is adhered to the resin molded product when the resin molded product is molded.

  According to the present invention, in insert molding using an optical reflective film that bears a surface decoration having a metallic tone, the optical reflective film has an effect of suppressing the occurrence of cracks in the optical reflective layer related to the decoration performance. It becomes possible to provide the manufacturing method which becomes possible [obtaining the molded article with high designability by using this for the injection molding by a film insert method].

  That is, by using the optical reflective film for insert molding obtained by forming an optical reflective layer on one surface of the plastic film, the optical reflective film and the molding resin in the injection mold are used. Integrated formation is possible. As a result, there is no need for waste liquid treatment for plating and painting.

  Further, by controlling the residual internal stress of the optical reflection film within an appropriate range, it is possible to obtain a molded product with few cracks and good appearance. Furthermore, since the hard coat layer for protecting the film surface is formed in advance on the optical reflective film for insert molding, a separate coating is unnecessary, and the production efficiency is good.

It is a typical sectional view explaining an example of an optical reflective film for insert molding concerning an embodiment based on the present invention. It is a typical sectional view explaining an example of an optical reflective film for insert molding made into the composition which has a buffer layer concerning an embodiment based on the present invention. It is the figure which showed the correlation with the residual internal stress of various optical reflective films, and the crack which arises in an optical reflective film by a bending test.

  Below, the manufacturing method of the insert molding optical reflection film 10 using the optical reflection film 10 for insert molding of the present invention of the present invention and the optical reflection film 10 for insert molding according to the present invention will be described.

(Optical reflection film for insert molding)
As shown in FIG. 1, the optical reflective film 10 for insert molding according to the present embodiment has an optical reflective layer 2 formed on one surface (the lower surface in FIG. 1) of a substrate 1 made of a plastic film. A colored layer 3 is formed on the layer 2. A hard coat layer 4 is formed on the other surface (the upper surface in FIG. 1) of the substrate 1.
The optical reflection layer 2 is composed of one or more metal films or metal compound films, and has a thickness of 200 nm to 400 nm. The residual internal stress of the optical reflection layer 2 is −300 MPa or more. The optical reflection layer 2 may have a laminated structure of two or more metal films or metal compound films, and at least two of them may be composed of a high refractive material and a low refractive material, respectively.

The colored layer 3 is a layer for the purpose of improving luster and heat absorption.
Here, as shown in FIG. 2, a buffer layer 5 may be interposed between the base material 1 and the optical reflection layer 2.

(Method for manufacturing insert molded products)
Manufacture of the insert molded product of this embodiment is implemented as follows.

First, the optical reflective film 10 for insert molding as described above is placed in an injection mold, and heated and vacuumed. Thus, the insert-molding optical reflective film 10 is processed into a three-dimensional shape having a large unevenness difference, and is in close contact with the cavity forming surface of the injection mold.
Next, the mold is clamped and a molding resin is injected into the cavity in the mold. Thus, the optical reflection film 10 is also bonded to the resin molded product when the resin molded product is molded.

(About each layer)
The base material 1 made of the plastic film is made of a material that can be processed into a three-dimensional shape having a large unevenness difference by being heated and vacuum-sucked to be in close contact with the cavity forming surface of the injection mold. As the substrate 1, polyethylene (polyethylene terephthalate, polyethylene naphthalate), olefin, acrylic, or polyimide can be used.

  In addition, it is good to use the base material 1 by which the hard-coat layer 4 was beforehand coated on one side (other side) in this case. In this case, it is not necessary to separately apply the hard coat layer 4 in a subsequent process, so that an increase in the number of processes and an increase in cost can be avoided.

  The optical reflection layer 2 is heated together with the base material 1 and is vacuum-sucked to be in close contact with the cavity forming surface of the injection mold. At this time, if a crack is generated when the optical reflection layer 2 is deformed into a three-dimensional shape, the design property is impaired. Therefore, it is necessary to suppress the generation of the crack. For this reason, the one where the film thickness of the said optical reflection layer 2 is thinner is preferable. However, since transparency occurs when the thickness is too thin, the thickness is desirably 200 nm or more and 400 nm or less.

  Note that the optical reflection layer 2 may have either a single layer film or a laminated film. In the case of aiming to obtain a single color metallic luster, it can be achieved by forming a single layer film from a metal film. On the other hand, when a surface glossiness with a metallic interference color is required, the optical reflection layer 2 is made of a laminated structure of metal compounds in order to obtain an interference effect due to multiple reflection at the laminated interface of the optical reflection layer 2. It is good to be done. In this case, in order to increase the surface reflectance by the interference effect due to the multiple reflection at the laminated interface, it is advantageous that the difference in the refractive index of each layer is large. Therefore, when the optical reflective layer 2 is produced with a laminated structure of two or more films, it is preferable to use a combination of a film made of a high refractive index material and a film made of a low refractive index material.

As a combination of a film made of a high refractive index material and a film made of a low refractive index material, for example, titanium oxide (TiO 2 ) as a high refractive index material and silicon dioxide (SiO 2 ) as a low refractive index material Or a combination of titanium oxide (TiO 2 ) as a high refractive index material and alumina (Al 2 O 3 ) as a low refractive index material, or as a high refractive index material. A laminated structure in which tantalum oxide (Ta 2 O 5 ) and silicon dioxide (SiO 2 ) as a low refractive index material are combined can be given.

  Further, the optical reflection layer 2 can be produced by an EB vapor deposition method or a sputtering method, and at this time, the adhesion with the base material 1 can be controlled by a substrate heating or an ion beam assist method. In addition, by performing film formation in which the residual internal stress of the optical reflective layer 2 produced by the EB vapor deposition method or sputtering method is controlled, the optical reflective film 10 for insert molding having the optical reflective layer 2 is formed. In the processing into a three-dimensional shape by vacuum suction in the used injection molding die and the subsequent injection molding, it is possible to delay the generation of cracks due to the optical reflection film 10 being stretched.

FIG. 3 shows a correlation between residual internal stresses of various optical reflecting films and cracks generated in the optical reflecting film 10 by a bending test. Here, the bending test is to observe a crack generated when the optical reflective film 10 is wound around a concentric rod having various diameters.
As seen in FIG. 3, TiO 2 / SiO 2 (hereinafter referred to as A film) and TiO 2 / Al 2 O 3 (hereinafter referred to as B film) are ZrO 2 / SiO 2 (hereinafter referred to as C film). Residual internal stress is small compared to In addition, the A film and the B film, which have low stress, are less likely to crack even when bending with a smaller curvature than the C film having a large residual internal stress. Therefore, it can be said that the optical reflection film having a smaller residual internal stress is superior in resistance to bending.

Furthermore, when the crack of the molded article produced by performing insert molding using the optical reflective film 10 obtained by forming the A film to the C film was observed, the C film has many cracks. On the other hand, the appearances of the A film and the B film are similar, and there are few cracks. This result corresponds to the result obtained by the bending test.
On the other hand, the residual internal stress of the C film is −450 MPa, the A film is about 10 MPa, and the B film is 160 MPa. From this result, it seems that it is effective for reducing the cracks caused by molding to set the residual internal stress of the optical reflecting film to −300 MPa or more.
That is, the residual internal stress of the optical reflection film can be set to −300 MPa or more and the crack generation curvature can be set to 3.0 or less. More preferably, the residual internal stress of the optical reflection film is controlled to 0 MPa or more.

The colored layer 3 is for absorbing and holding heat efficiently, and for maintaining the metallic brightness of the optical reflecting layer 2. The colored layer 3 can be formed by a printing method using a urethane-based resin.
In addition, in the optical reflective film 10 for insert shaping | molding, as shown in FIG. 2, it is also possible to set it as the structure which formed the buffer layer 5 between the base material 1 used as the base material 1, and the optical reflection layer 2. As shown in FIG. By providing the buffer layer 5, the effect of blocking the influence of deformation due to thermal expansion and contraction of the base material 1, which is the base material 1, is transmitted to the optical reflection layer 2. For this reason, it is effective at the point which can suppress generation | occurrence | production of the crack in the optical reflection layer 2. FIG. The buffer layer 5 may be either organic or inorganic, and is preferably as thin as possible.

  Hereinafter, an optical molding film 10 for insert molding of the present invention and a process for producing a resin molded product by insert molding using the same will be described with reference to examples.

The plastic film used as the substrate 1 was a 125 μm thick PET film coated with a hard coat on one side. The optical reflection layer 2 was formed by stacking titanium oxide (TiO 2 ) and silicon dioxide (SiO 2 ) by a sputtering method to form a film having a total thickness of 280 nm. At this time, the residual internal stress of the optical reflection layer 2 was −150 MPa. Then, the optical reflective film 10 for insert molding of this invention was obtained by forming a printing layer restrained on this by screen printing.

  The optical reflective film 10 for insert molding having the above-mentioned layer structure is temporarily wound to form a roll-shaped roll, and the optical reflective film 10 is unwound from the roll-shaped roll and continuously on the front surface of the cavity forming surface of the injection mold. Inserted.

  Next, the optical reflective film 10 is fixed by a clamp member around the cavity forming surface and softened so that the film surface temperature becomes 100 ° C., and the space between the optical reflective film 10 and the cavity forming surface is vacuumed. By sucking, the optical reflecting film 10 was brought into close contact with the cavity forming surface of the injection mold.

Next, an acrylic resin having a molding temperature of 220 to 250 ° C. was injection molded as a molding resin into a cavity obtained by clamping the mold.
After cooling the resin molded product, it was taken out from the mold. When the appearance was confirmed, it was confirmed that a blue-colored telephone commercial product with a hard coat with few cracks and good appearance was obtained.

Except for producing the optical reflection layer 2 by EB vapor deposition, titanium oxide (TiO 2 ) and silicon dioxide (SiO 2 ) are formed in a laminated structure by the same process as in Example 1, and from six layers in total. A 300 nm thick film was formed. At this time, the residual internal stress of the optical reflection layer 2 was −120 MPa. Then, the optical reflective film 10 for insert molding of this invention was obtained by forming a printing layer restrained on this by screen printing. Thereafter, injection molding was performed by the same process as in Example 1. And when the external appearance was confirmed, it was confirmed that a blue form telephone commercial product with a hard coat with few cracks and a good external appearance was obtained.

A process similar to that of Example 1 was performed except that a film having a thickness of 320 nm consisting of six layers was formed in a laminated structure of titanium oxide (TiO 2 ) and alumina (Al 2 O 3 ). A reflective layer 2 was formed. At this time, the residual internal stress of the optical reflection layer 2 was 160 MPa. Then, the optical reflection film 10 for insert molding based on this invention was obtained by forming a printing layer restrained on this by screen printing. Thereafter, injection molding was performed by the same process as in Example 1. And when the external appearance was confirmed, it was confirmed that a blue form telephone commercial product with a hard coat with few cracks and a good external appearance was obtained.

A film of titanium oxide (TiO 2 ) and alumina (Al 2 O 3 ) having a thickness of 340 nm in total of 6 layers is formed by the same process as in Example 1 except that the optical reflection layer 2 is produced by EB vapor deposition. The optical reflection layer 2 was formed by the same process as in Example 1 except that it was formed. At this time, the residual internal stress of the optical reflection layer 2 was 85 MPa. Then, after forming the colored layer 3 on this by screen printing, after obtaining the optical reflective film 10 for insert molding of this invention, the injection molding was performed by the process similar to Example 1. FIG. And when the external appearance was confirmed, it was confirmed that a blue form telephone commercial product with a hard coat with few cracks and a good external appearance was obtained.

DESCRIPTION OF SYMBOLS 1 Base material 2 Optical reflection layer 3 Colored layer 4 Hard-coat layer 5 Buffer layer 10 Optical reflection film for insert molding

Claims (6)

  1.   An optical reflective layer made of one or more metal films or metal compound films and having a thickness of 200 nm or more and 400 nm or less is formed on one surface of a substrate made of a plastic film, and the glitter is improved on the optical reflection layer, and An optical reflective film for insert molding, wherein a colored layer for the purpose of improving heat absorption is formed.
  2.   The optical reflective film for insert molding according to claim 1, wherein the residual internal stress of the optical reflective layer is −300 MPa or more.
  3.   The optical reflective film for insert molding according to claim 1 or 2, wherein a hard coat layer is formed on the other surface of the substrate.
  4.   The insert reflective optical reflective film according to any one of claims 1 to 3, wherein a buffer layer is interposed between the base material and the optical reflective layer.
  5.   The optical reflection layer has a laminated structure of two or more layers, and at least two of the optical reflection layers are each composed of a high refractive material and a low refractive material. The optical reflective film for insert molding according to any one of the above.
  6.   The optical reflective film for insert molding according to any one of claims 1 to 5 is installed in an injection mold and processed into a three-dimensional shape having a large unevenness by heating and vacuum suction. Then, after the optical reflective film for insert molding is brought into close contact with the cavity forming surface of the injection mold, the mold is clamped and the molding resin is injected into the cavity in the mold, thereby forming a resin molded product. A method for producing an insert-molded product, characterized in that an optical reflective film is adhered to a resin molded product.
JP2010078576A 2010-03-30 2010-03-30 Optical reflective film for insert molding and method for producing insert molded product using the same Active JP5640428B2 (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014000745A (en) * 2012-06-20 2014-01-09 Reiko Co Ltd Metallic molded product and transfer film used for the same
WO2018207623A1 (en) * 2017-05-10 2018-11-15 コニカミノルタ株式会社 Reflective film, reflective optical element, method for forming reflective optical element and method for producing reflective film

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10264201A (en) * 1997-03-24 1998-10-06 Nissha Printing Co Ltd Metal vapor deposition insert film and production of metal deposition insert molded product
JP2005254531A (en) * 2004-03-10 2005-09-22 Pacific Ind Co Ltd Metal tone molded sheet and its production method
JP2005288720A (en) * 2004-03-31 2005-10-20 Toppan Printing Co Ltd Insert film and molded product using it
JP2008275737A (en) * 2007-04-26 2008-11-13 Toppan Printing Co Ltd Optical thin film layered product

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10264201A (en) * 1997-03-24 1998-10-06 Nissha Printing Co Ltd Metal vapor deposition insert film and production of metal deposition insert molded product
JP2005254531A (en) * 2004-03-10 2005-09-22 Pacific Ind Co Ltd Metal tone molded sheet and its production method
JP2005288720A (en) * 2004-03-31 2005-10-20 Toppan Printing Co Ltd Insert film and molded product using it
JP2008275737A (en) * 2007-04-26 2008-11-13 Toppan Printing Co Ltd Optical thin film layered product

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014000745A (en) * 2012-06-20 2014-01-09 Reiko Co Ltd Metallic molded product and transfer film used for the same
WO2018207623A1 (en) * 2017-05-10 2018-11-15 コニカミノルタ株式会社 Reflective film, reflective optical element, method for forming reflective optical element and method for producing reflective film

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