JP2011251542A - Decorative sheet for molding and method for producing decorative molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet for molding used for molding, which can secure the adhesion between a substrate sheet and an acrylic resin layer and can more easily follow elongation generated during the sheet molding.SOLUTION: The decorative sheet for molding, used for decorating a decorative molding is composed of: the substrate sheet as a support; the acrylic resin layer formed above the substrate sheet; a pattern layer which is formed on at least one of the surface of acrylic resin layer and the surface of substrate sheet in between the substrate sheet and the acrylic resin layer; and a polyester urethane resin layer which is formed on the surface of pattern layer and comes in contact with both the substrate sheet and the acrylic resin layer to join the both, wherein the decorative molding is produced by mold-integrating the decorative sheet for molding and an adherend.

Description

  The present invention relates to a decorative sheet for molding, a method for manufacturing a decorative molded product, in particular, a decorative sheet for molding used for decorating a decorative molded product manufactured integrally with an adherend, and a decoration using the same. The present invention relates to a method for manufacturing a molded product.

  There are known decorative molded products used for interiors of buildings, interiors of joinery, interiors of vehicles, and the like. The decorative molded product is manufactured by inserting a decorative sheet for molding on which a pattern layer has been formed into a cavity of a molding machine, filling the cavity with a resin in a fluid state after insertion, and solidifying the resin to form a resin. It is common to manufacture a product by integrating a resin-shaped product and a decorative sheet for molding.

2. Description of the Related Art Conventionally, molding decorative sheets are formed on a three-dimensional surface of an adherend such as a resin molded product, laminated, and decorated. For example, it is decoration by a molding decoration technique such as an injection molding simultaneous lamination method described in the following Patent Document 1 or a vacuum forming lamination method described in the following Patent Document 2.
As a sheet for molding decoration used in such molding decoration technology, (1) a pattern by printing on the back surface of a transparent substrate sheet made of a thermoplastic resin such as acrylic resin, ABS resin, polycarbonate resin, polyolefin resin, etc. Pattern ink layer on a decorative base sheet made of a thermoplastic resin to which a decorative layer such as an ink layer is provided and the resin sheet is a single layer structure, and (2) a concealing colorant is added. A decorative sheet such as a decorative layer and a transparent base material sheet made of a thermoplastic resin were laminated, and there was a molded decorative sheet having a laminated structure of resin sheets.

  The decorative sheet for molding described in Patent Document 3 below is an acrylic sheet in which a pattern layer is provided on an acrylic resin layer, and an adhesive ink layer mainly composed of a vinyl resin or an acrylic resin is provided thereon. A resin layer and a base sheet of acrylonitrile butadiene styrene are laminated thereon.

  In the decorative sheet for molding as described in Patent Document 3, an acrylic resin layer having an adhesive ink layer mainly composed of a vinyl resin or an acrylic resin is used as a base sheet and a vinyl resin or an acrylic resin. It is integrated by thermal lamination through an adhesive ink layer containing as a main component. In this document, the adhesion between the acrylic resin layer and the substrate sheet is improved by the adhesive ink layer.

Japanese Patent Publication No. 50-19132 Japanese Patent Publication No. 60-58014 Japanese Patent Laid-Open No. 11-91041

  However, even if the adhesion between the base sheet and the base material sheet can be ensured, the adhesive ink layer mainly composed of a vinyl resin or an acrylic resin cannot follow the elongation that occurs during sheet molding, and the adjacent layer (for example, a decorative layer) May cause flow, deformation, breakage, etc. in the decorative layer. If flow, deformation, or cutting occurs, the adhesive strength between the base sheet and the acrylic resin layer may decrease due to these.

  The present invention has been made in view of solving the above-described problems, and is capable of ensuring adhesion between the base sheet and the acrylic resin layer, and more easily decorating the elongation generated during sheet molding. The main purpose is to provide seats.

  The present invention is a decorative sheet for molding that is used for decorating a decorative molded product that is manufactured by being integrated with a resin in a fluid state, and is more than a base sheet that serves as a support, and the base sheet An acrylic resin layer formed on an upper layer, and a pattern layer formed between at least one of the surface of the acrylic resin layer and the surface of the base material sheet, between the base material sheet and the acrylic resin layer; And a polyester urethane resin layer formed on the surface of the design layer and in contact with at least one of the base sheet and the acrylic resin layer.

  The main component of the substrate sheet is preferably a polypropylene resin or an ABS resin.

  The present invention is a method for manufacturing a decorative molded product, which is manufactured by integrating a resin in a fluid state with the decorative sheet for molding according to claim 1, wherein the decorative sheet for molding is disposed in a molding machine. An insertion step of inserting into the cavity portion, a filling step of filling the cavity portion with the resin in the fluid state after the insertion, and solidifying the resin in the fluid state into a resin molded product, the resin molded product and the molding And an integration step for integrating the decorative sheet.

  The filling is preferably performed by injecting the resin in the fluid state into the cavity portion.

  According to the present invention, the adhesiveness between the base sheet and the acrylic resin layer can be secured, the adhesiveness between the base sheet and the acrylic resin layer can be secured, and it is easier to follow the elongation that occurs during sheet molding. A decorative sheet for molding can be provided.

It is typical sectional drawing of the decorating sheet for shaping | molding in this embodiment. It is a schematic diagram which shows an example of the printing pattern in this embodiment. It is a schematic diagram which shows the manufacturing method of the decoration molded product using the decoration sheet for shaping | molding in this embodiment.

  This inventor examined the decorative sheet for shaping | molding used for the decoration of the decorative molded product manufactured by integrating | bonding with a to-be-adhered body and shaping | molding. The decorative sheet for molding examined by the present inventors includes a base sheet and an acrylic resin layer, and a pattern layer is formed on at least one surface of the acrylic resin layer surface and the base sheet surface. It is a decorative sheet for molding.

  As a result of examining the resin layer formed on the surface of the design layer and contacting at least one of the base sheet and the acrylic resin layer, the decorative sheet for molding is preferably a polyester urethane resin layer. I found.

  In the decorative sheet for molding formed in such a manner that the polyester urethane resin layer is formed on the surface of the design layer and is in contact with at least one of the base sheet and the acrylic resin layer, there is no polyester urethane resin layer, and the base sheet It is possible to ensure better adhesion than direct contact between the acrylic resin layer and the acrylic resin layer, as well as the resin layer mainly composed of vinyl resin or acrylic resin, which can be more suitably followed by the elongation that occurs during molding. It is possible to more suitably prevent the resin layer or other decorative sheet for molding (for example, when a decorative layer is provided) from flowing, deforming, or cutting. By this prevention, it is possible to more suitably prevent the adhesive strength between the base sheet and the acrylic resin layer from being lowered due to flow, deformation, cutting, or the like.

  Further, the inventor of the present invention provides a molding sheet in which a polyester urethane resin layer is formed on the surface of a design layer and is in contact with at least one of the base sheet and the acrylic resin layer. The method of integrating the two layers with the layer may be thermal lamination, dry lamination, other known lamination methods, or melt extrusion. It has also been found that it is preferable to use thermal lamination and dry lamination, that is, to perform thermal lamination using a dry lamination adhesive while applying heat.

"Decoration sheet for molding"
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, about this embodiment, it is only one form for implementing this invention, and this invention is not limited by this embodiment.

  Hereinafter, the decorative sheet for molding 100 according to the embodiment will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view showing an example of the decorative sheet for molding 100 of the present invention. 1 includes an acrylic resin layer 10 and a base material sheet 20 that reinforces the acrylic resin layer 10, a design layer 18 formed on the lower surface of the acrylic resin layer 10, and a design layer 18 or acrylic. The polyester urethane resin layer 15 is formed between the resin layer 10 and the base sheet 20.

(Acrylic resin layer)
The acrylic resin layer 10 is mainly made of an acrylic resin, and an acrylic resin in general can be used as the acrylic resin used. Examples of acrylic resins include poly (meth) methyl acrylate, poly (meth) ethyl acrylate, poly (meth) acrylate propyl, poly (meth) acrylate butyl, methyl (meth) acrylate- (meth) acryl Such as butyl acrylate copolymer, (meth) ethyl acrylate- (meth) butyl acrylate copolymer, ethylene- (meth) methyl acrylate copolymer, styrene- (meth) methyl acrylate copolymer (meta ) A resin comprising a homopolymer or a copolymer containing an acrylate ester. In addition, (meth) acryl means acryl or methacryl. These acrylic resins can be used alone or as a mixture of two or more.

  The thickness of the acrylic resin layer 10 is preferably in the range of 50 to 250 μm, more preferably 80 to 150 μm from the viewpoints of cost, moldability (shape followability, wrinkle generation prevention, etc.), and handleability. Good.

  The acrylic resin layer 10 is a layer provided on the outermost layer or the immediate lower layer of the decorative sheet for molding of the present embodiment, and is also referred to as a topcoat layer or an overprint layer (OP layer). When embossing is formed on the surface, the surface of the decorative sheet for molding is protected by covering the recessed part that forms the emboss, and the decorative sheet for molding is resistant to contamination, abrasion, etc. It may play a role of imparting durability or gloss.

  In this way, the acrylic resin layer 10 provided on the surface may contain a crosslinkable resin for protecting the surface. The layer containing the cross-linking agent is formed by the cross-linking agent-containing coating agent. In addition, a resin layer containing a crosslinkable resin as another layer may be formed on the surface of the acrylic resin layer 10 to improve weather resistance. As a coating method, the above-listed compositions may be liquefied and appropriately selected from known methods for application.

  As the crosslinkable resin, an ionizing radiation curable resin is preferably used. Since the acrylic resin layer 10 is formed of an ionizing radiation curable resin and cured with high energy rays such as ionizing radiation, the crosslinkability of the layer constituting the acrylic resin layer 10 is increased. The surface physical properties of the decorative sheet for molding such as property are improved. It is also possible to use materials other than the ionizing radiation curable resin.

  As the crosslinkable resin, a resin obtained by a crosslinking reaction using at least one of urethane acrylate, epoxy acrylate, acrylic polyol and polyester acrylate and a curing agent, and an ionizing radiation curable resin described later as it is or using a curing agent And a cross-linked and cured resin. As the coating agent for forming the layer, at least one kind of crosslinkable resin selected from these resins can be used. Among these resins, it is preferable to use a resin obtained by a crosslinking reaction with at least one selected from urethane acrylate, epoxy acrylate, acrylic polyol and polyester acrylate and a curing agent.

  As a curing agent used to obtain a crosslinkable resin, usually isocyanates or organic sulfonates are used for unsaturated polyester resins and polyurethane resins, amines are used for epoxy resins, and further as a radical polymerization initiator, Methyl ethyl ketone peroxide or azobisisobutyl nitrile is used.

  As the isocyanate, divalent or higher aliphatic or aromatic isocyanate can be used, and specific examples include tolylene diisocyanate, xylene diisocyanate, 4,4-diphenylmethane diisocyanate, hexamethylene diisocyanate, lysine diisocyanate and the like.

  The ionizing radiation curable resin is a resin that has an energy quantum capable of polymerizing and crosslinking molecules among electromagnetic waves or charged particle beams, and can be cured by ionizing radiation such as ultraviolet rays and electron beams, and is polymerized in the molecules. A composition in which prepolymers, oligomers, and / or monomers having a polymerizable unsaturated bond or an epoxy group are appropriately mixed is used. Examples of these compositions include acrylates such as urethane acrylate, polyester acrylate, and epoxy acrylate, silicon resins such as siloxane, polyester resins, unsaturated polyester resins, epoxy resins, phenol resins, and polyurethane resins. Among these, it is preferable to use an acrylate ionizing radiation curable resin, and high crosslinkability, excellent wear resistance, and contamination resistance can be imparted to the layer constituting the acrylic resin layer 10.

  The above compounds can be used singly or in combination of two or more as required. In selecting a monomer, if the cured product is required to be flexible, the amount of the monomer is reduced within a range that does not hinder coating suitability, or a monofunctional or bifunctional acrylate-based monomer is used. A structure having a relatively low crosslinking density is obtained using a monomer. In addition, when the heat resistance, hardness, solvent resistance, etc. of the cured product are required, the amount of monomer is increased within a range that does not hinder coating suitability, or an acrylate monomer having three or more functions is added. It is preferable to use a high crosslink density structure. It is also possible to adjust coating suitability and physical properties of the cured product by mixing a 1,2-functional monomer and a tri- or higher functional monomer. Examples of the monofunctional acrylate monomer as described above include 2-hydroxy acrylate, 2-hexyl acrylate, phenoxyethyl acrylate, and the like. Examples of the bifunctional acrylate monomer include ethylene glycol diacrylate and 1,6-hexanediol acrylate, and examples of the trifunctional or higher acrylate monomer include trimethylolpropane triacrylate, pentaerythritol hexaacrylate, diester. Examples include pentaerythritol hexaacrylate.

  When the ionizing radiation curable resin obtained as described above is used as a crosslinkable resin, it preferably has a functional group that reacts with a curing agent, and the functional group includes an OH group, an SH group, an amino group, a carboxyl group, and an epoxy group. Etc. However, even when these functional groups are not present, they can be used after being cured by polymerization if they have a polymerizable unsaturated double bond. That is, the crosslinkable resin includes a resin that is crosslinked using a curing agent and a resin that is cured by radical polymerization without using a curing agent. For example, when urethane acrylate, epoxy acrylate, acrylic polyol, or the like is used. The OH group and the epoxy group are cured by causing a crosslinking reaction with a curing agent, and the double bond of the acrylic group is cured by radical polymerization. Therefore, in the crosslinkable resin after curing, the crosslinking reaction product and the polymerization product may be generated separately, and there may be a structure caused by crosslinking and a structure caused by polymerization in the same molecule. Further, if a polymerizable double bond exists in each of the crosslinking reaction product and the polymerization product, both reaction products may cause a polymerization reaction to form one molecule.

  In order to form the acrylic resin layer 10, a resin, prepolymer or oligomer having a functional group or / and a polymerizable double bond used for the above-described crosslinkable resin is applied as a mixture in which a curing agent or a polymerization catalyst is mixed. You can also. Moreover, it can also apply | coat after hardening of this mixture progresses and it reaches | attains viscosity suitable for application | coating.

  Examples of the additive include a matting agent, a photopolymerization initiator, and a photosensitizer. By using a matting agent as an additive, the matte effect of the formed acrylic resin layer 10 can be obtained. Examples of the matting agent include inorganic or organic fillers or fine powders such as silica, calcium carbonate, barium sulfate, alumina, glass balloon, and polyethylene. The shape of the matting agent is arbitrary, but is preferably spherical or substantially spherical. The particle size of the matting agent can be about 0.1 to 10 [mu] m, but the maximum particle size is preferably 9 to 10 [mu] m. When the maximum particle size is in the range of 9 to 10 μm, it can be uniformly dispersed to form a beautiful matte surface (matte surface), and the surface is relatively smooth without forming conspicuous irregularities on the surface. It is formed. When the matting agent is contained in the ionizing radiation curable resin composition, the matting agent is mixed and dispersed.

  When the above-mentioned ionizing radiation curable resin composition is cured with ultraviolet rays in particular, acetophenones, benzophenones, Michler benzoyl benzoate, α-amyloxime ester are used as photopolymerization initiators in the ionizing radiation curable resin composition. , Tetramethylthiuram monosulfide, thioxanthones, and / or n-butylamine, triethylamine, tri-n-butylphosphine and the like can be used as a photosensitizer.

(Design layer)
The pattern layer 18 is not particularly limited, and may be based on a method of forming a pattern, but in the present embodiment, as an example, it is a printed layer printed on the lower surface side of the acrylic resin layer 10. Note that the symbols are not limited to pictures and drawings, but include all forms such as letters and numbers.

  As a material of the pattern layer 18, a binder 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 an appropriate color pigment or dye as a colorant may be used.

  The design layer 18 may be embossed and given design properties by embossing. The film thickness at that time can be determined by comparative consideration of the balance between the ease of ink image reception and the film thickness that can properly represent the concavo-convex pattern layer when embossing is performed. The thickness of the pattern layer 18 is preferably formed in the range of 0.5 to 50 μm. If it is thinner than 0.5 μm, it may be influenced by the color of the molding resin after molding. If it is thicker than 50 μm, the residual solvent is difficult to volatilize, and the acrylic resin layer 10 may be eroded and mechanical strength such as tensile strength and bending strength may be lowered.

  The design layer may be composed of a metal thin film layer or a combination of a design layer and a metal thin film layer. The metal thin film layer is for expressing metallic luster, and is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. Metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, and zinc, and alloys or compounds thereof are used depending on the metallic luster color to be expressed. In the present application, layers formed by these methods are also included in the design layer.

  In the present embodiment, the design layer is provided on the lower layer side surface of the acrylic resin layer, but is not limited thereto. It may be formed only on either the upper layer side or the lower layer side or on both sides. Further, the design layer may not be provided on the surface of the acrylic resin layer itself. For example, a design layer may be provided on the base sheet side.

  As in the present embodiment, the pattern layer may be formed by a plurality of layers discontinuously in the lateral direction, or may be continuously formed by a single layer in the lateral direction, and is particularly limited. Never happen.

  The pattern shape of the pattern layer can be easily dealt with by generating an image of an arbitrary shape by known digital image processing on a computer, for example, when printing a manuscript or printing plate when it is a printing layer. it can. If the pattern shape is further deformed, a pattern expressing a design pattern as a dual-purpose decorative layer or a position-synchronized decorative layer can be obtained. The pattern pattern expressed by the decoration layer may be any pattern as long as it suits the application. For example, wood grain pattern, stone pattern, cloth pattern, tile-like pattern, brick-like pattern, leather-drawn pattern, geometric pattern, abstract pattern (for example, gradation pattern), character, micro letter, symbol, mark, figure, etc. is there.

  As the discontinuous pattern, the shape of the non-formed portion of the design layer 18 (the surface that becomes an opening with respect to the design layer and the surface of the acrylic resin layer 10 is exposed) is the print forming portion 61 as shown in FIG. Depending on the square (A), hexagon (B), triangle (C), shape sandwiched between parallel lines (D), rectangle (E), octagon, other polygons, or rounded corners in these polygons It is represented by a certain shape, a circle, an ellipse, or a combination of these shapes. Further, the arrangement of these shapes can be made in a staggered manner by adjusting the arrangement in addition to a square lattice arrangement.

  The formation method of the pattern layer 18 can be appropriately selected according to the surface physical properties of the acrylic resin layer 10 on the surface to be formed.

(Polyester urethane resin layer)
A polyester urethane resin layer 15 is formed on the lower layer surface of the pattern layer 18. The polyester urethane resin layer 15 is a layer that improves the adhesion between the base material sheet 20 and the acrylic resin layer 10 more than when the polyester urethane resin layer 15 is not provided.

  The polyester urethane which is the main component of the polyester urethane resin layer 15 may be prepared by an existing reaction. The polyester urethane resin comprises a polyester polyol obtained by esterifying a dicarboxylic acid and a diol component, a polyisocyanate, and, if necessary, a chain extender.

  Dicarboxylic acid components include terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, adipic acid, trimethyladipic acid, sebacic acid, malonic acid, dimethylmalonic acid, succinic acid, glutaric acid, pimelic acid, 2,2- Dimethylglutaric acid, azelaic acid, fumaric acid, maleic acid, itaconic acid, 1,3-cyclopentanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, 1,4-naphthalic acid, diphenine Acid, 4,4′-oxybenzoic acid, 2,5-naphthalenedicarboxylic acid and the like can be used.

  Examples of the diol component include aliphatic glycols such as ethylene glycol, 1,4-butanediol, diethylene glycol, and triethylene glycol, aromatic diols such as 1,4-cyclohexanedimethanol, polyethylene glycol, polypropylene glycol, and polytetramethylene glycol. Examples include poly (oxyalkylene) glycol.

  In addition to the dicarboxylic acid component and the diol component, oxycarboxylic acid such as p-oxybenzoic acid may be copolymerized. Furthermore, these are linear structures, but trivalent or higher valent ester forming components are used. Branched polyester can also be obtained.

  Polyisocyanates include hexamethylene diisocyanate, diphenylmethane diisocyanate, tolylene diisocyanate, isophorone diisocyanate, tetramethylene diisocyanate, xylylene diisocyanate, adduct of tolylene diisocyanate and trimethylol propane, addition of hexamethylene diisocyanate and trimethylol ethane. Things can be mentioned.

  Examples of the chain extender include pendant carboxyl group-containing diols and glycols such as ethylene glycol, diethylene glycol, propylene glycol, 1,4-butanediol, hexamethylene glycol, neopentyl glycol, or ethylenediamine, propylenediamine, Examples include diamines such as methylenediamine, phenylenediamine, tolylenediamine, diphenyldiamine, diaminodiphenylmethane, diaminodiphenylmethane, and diaminocyclohexylmethane.

  More specifically, for example, polyester urethane is obtained by reaction of a polyisocyanate compound and a polyether polyol. Polyether polyols include polyhydric alcohols such as polypropylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol and sucrose, amines such as ethylenediamine, ethanolamine and aromatic polyamine, and polyhydric phenols such as phenolic resin. As a starting material, an alkylene oxide obtained by ring-opening polymerization is used. Polyisocyanates include tolylene diisocyanate, polymethylene polyphenyl polyisocyanate, 4,4-diphenylmethane diisocyanate, 1,5-naphthalene diisocyanate, triphenylmethane triisocyanate, tolidine diisocyanate, xylene diisocyanate, hexamethylene diisocyanate, norbornene diisocyanate dicyclohexylmethane. Examples thereof include diisocyanate and isophorone diisocyanate. As a commercial item, bihydrol PR135 (Sumika Bayer Urethane Co., Ltd.) is mentioned, for example.

  More specifically, for example, polyester urethane and polyester urethane resin may be obtained by reaction of a polyisocyanate compound and a polyester polyol. Polyester polyol is generally produced from dicarboxylic acid and glycol, and has a hydroxyl group at the end of the molecule. Examples of the dicarboxylic acid include adipic acid, phthalic acid, sebacic acid, and dimer acid. Examples of the glycol include ethylene glycol, diethylene glycol, propylene glycol, butylene glycol, 1,3-butanediol, hexanetriol, trimethylolpropane, and caprolactone. And ring-opening polymerized types of esters. As polyisocyanate, what was illustrated previously as a raw material of polyether urethane resin is used. Examples of commercially available products include Bihydrol PR240 (Sumika Bayer Urethane Co., Ltd.).

  The polyester urethane resin layer is preferably 0.5 to 10 μm in dry film thickness.

(Substrate sheet)
The substrate sheet 20 is not particularly limited, but is polyethylene (low density or high density), polypropylene (isotactic type, syndiotactic type, or a mixed type thereof), polymethylpentene, polybutene, ethylene-propylene. High crystalline non-elastomeric polyolefin resin such as copolymer, ethylene-vinyl acetate copolymer, propylene-butene copolymer, or various olefinic thermoplastic elastomers described below, ABS (acrylonitrile-butadiene-styrene copolymer) (Polymer) A resin sheet is preferably used. Other examples include polystyrene, acrylonitrile-styrene copolymer, and the like.

  The ABS resin is grafted with styrene and acrylonitrile in the presence of a polymer blend type of styrene-acrylonitrile copolymer and NBR (nitrile rubber) and BR (polybutadiene rubber) or SBR (styrene-butadiene rubber) latex. There are two types, a graft type obtained by copolymerization, both of which can be used, and the term “ABS resin” includes both.

  In the ABS resin, since butadiene has a rubber property and is easily stretched, it is preferable to set the content ratio of butadiene to 20 to 50% by weight. More preferably, it is 30 to 45% by weight.

  The manufacturing method of each layer in the decorative sheet for molding in the present embodiment is not particularly limited. For example, as a printing method, gravure coating, gravure reverse coating, comma coating, die coating, lip coating, cast coating, roll coating, Air knife coat, Mayer bar coat, extrusion coat, offset, UV curing offset, flexo, stencil, silk, curtain flow coat, wire bar coat, reverse coat, gravure coat, kiss coat, blade coat, smooth coat, spray coat, pouring Various printing methods such as coating and brushing can be applied. In addition to coating the lower layer as a dry film, the lower layer and the upper layer can be dried in two layers in a wet state.

  As these coating agents, it is also possible to use a solventless type coating agent that does not use a solvent. Solvent-free coating agents are those that are environmentally friendly and are preferably used.

  Examples of binder resins include vinyl resins such as ethyl cellulose, hydroxyethyl cellulose, ethyl hydroxy cellulose, hydroxypropyl cellulose, methyl cellulose, polyvinyl acetate, polyvinyl butyrate, polyvinyl acetal, polyvinyl pyrrolidone, polystyrene resins, and styrene-acrylic copolymers. System resin or the like is used.

  Binder resins for aqueous coating agents include (meth) acrylic monomers such as acrylic esters, methacrylic esters, hydroxyethyl acrylate, hydroxyethyl methacrylate, nitrile monomers such as acrylonitrile, methacrylonitrile, acrylamide, methacrylamide, etc. Amide monomers, N-alkoxy substituted products, N-methylol substituted products of the amide monomers, styrene monomers such as styrene, vinyl toluene, α-methyl styrene, divinyl benzene, diallyl phthalate, allyl glycidyl ether, tri One or more allyl monomers such as allyl isocyanurate, monomers having a polymerizable double bond such as vinyl acetate and N-vinylpyrrolidone, acrylic acid having a carboxyl group, and methacrylate. It is possible to use an alkali solution-soluble (meth) acrylic copolymer comprising a copolymer with one or more unsaturated carboxylic acids such as acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, etc. it can. In addition, polyallylamide resin, poly (meth) acrylic acid resin, polyethylene oxide resin, poly N-vinylpyrrolidone resin, water-soluble polyurethane resin (two-component curable polyurethane resin), water-soluble polyester resin Water-soluble synthetic resins such as resins, water-soluble polyamide resins, water-soluble amino resins, water-soluble phenol resins, etc., water-soluble natural polymers such as polynucleotides, polypeptides, polysaccharides, etc. are also used. be able to. Examples of other binder resins for aqueous coating agents include natural rubber, synthetic rubber, polyvinyl acetate resin, (meth) acrylic resin, polyvinyl chloride resin, polyurethane resin, and polyurethane-polyacrylic. Resin-modified or mixed resins, and other resins can be used. Also, urethane-based resins such as acrylic-modified urethane resins, polyester-modified urethane resins, vinyl chloride-vinyl acetate copolymer-modified urethane resins, polyol resins, or mixed resins of vinyl chloride-vinyl acetate copolymers and acrylic resins. Etc. are preferably used. The binder resin for the aqueous coating agent is made aqueous by dissolution, emulsification, microencapsulation, or other methods, and used for the aqueous coating agent. Binder resins for solvent-based coating agents include chlorinated polyolefin resins such as chlorinated polyethylene and chlorinated polypropylene, polyester resins, polyurethane resins, acrylic resins, vinyl acetate resins, vinyl chloride / vinyl acetate copolymers, and cellulose resins. Etc., and one or more of these may be used in combination.

  The solvent is not particularly limited, for example, toluene, xylene, ethyl acetate, butyl acetate, methyl ethyl ketone, methyl isobutyl ketone, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether and other water-insoluble organic solvents, methanol, Water-soluble organic solvents such as ethanol, isopropyl alcohol, and normal propyl alcohol, water, or mixed solvents thereof are used.

  As a solvent for the aqueous coating agent, water-soluble organic solvents such as water and alcohol can be used. As the water, ordinary industrial water can be used. Further, as a water-soluble organic solvent composed of water and alcohol, it can be prepared using water, lower alcohols such as methanol, ethanol, isopropyl alcohol and N-propyl alcohol, glycols and esters thereof, and the like. . The lower alcohol, glycols and esters thereof are preferably contained in a proportion of about 5 to 20% by weight. These solvents such as lower alcohols, glycols and esters thereof are used for the purpose of improving the fluidity of the ink, improving the wetness of the substrate sheet as the printing medium, and adjusting the drying property. Yes, the type, amount used, etc. are determined according to the purpose. The solvent of the solvent-based coating agent is not particularly limited, and examples thereof include non-toxic solvents such as toluene, xylene, ethyl acetate, butyl acetate, methyl ethyl ketone, methyl isobutyl ketone, ethylene glycol monomethyl ether, and ethylene glycol monoethyl ether. A water-soluble organic solvent or a mixed solvent thereof is used.

  Examples of the additive include an antistatic agent, a release agent, a colorant, and a conductive agent. Here, for example, when conductivity is imparted, an electromagnetic wave shielding function can be provided.

  Each layer constituting the decorative sheet for molding 100 can be used by mixing a wax component to such an extent that the scratch resistance is not impaired. Examples of the wax include microcrystalline wax, carbana wax, and paraffin wax. In addition, Fischer-Tropsch wax, various low molecular weight polyethylene, wood wax, beeswax, ibota wax, wool wax, cerax wax, candelilla wax, petrolactam, polyester wax, partially modified wax, fatty acid ester, fatty acid amide, etc. A wax etc. are mentioned.

  Each layer, for example, the resin layer, constituting the decorative sheet for molding 100 may contain 0.1 to 10% by weight, preferably 0.5 to 8% by weight of an ultraviolet absorber. The ultraviolet absorber is not particularly limited as long as it is a conventionally known one, but as the ultraviolet absorber, for example, benzophenone-based, benzotriazole-based, and cyanoacrylate-based ones are preferable. Examples of the benzophenone compounds include 2,3′-dihydroxy-4,4′-dimethoxybenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone and 2,2 ′, 4,4′-tetrahydroxybenzophenone. Can be mentioned.

  In addition to the above wax components and ultraviolet absorbers, additives such as colorants, antioxidants, heat stabilizers, leveling agents, coupling agents, and modifiers are added as necessary, or decorative sheets for molding It can also be added within a range that does not impair the overall properties.

  The colorant used as an additive plays a role of giving the molding decorative sheet 100 the color necessary for the molding decorative sheet. A coloring agent can be selected according to the use, and the decorative sheet for molding can be colored colored or transparently colored. Since it is necessary to conceal the surface of the adherend generally used for the base sheet 24, it is preferable that the base sheet 24 be colored and opaque with a colorant.

  Coloring agents include titanium white, zinc white, petal, vermilion, ultramarine blue, cobalt blue, titanium yellow, carbon black and other inorganic pigments, isoindolinone, banza yellow A, quinacridone, permanent red 4A, phthalocyanine blue, and other organic pigments. A pigment or dye, a metal pigment made of foil powder such as aluminum or brass, a pearlescent pigment made of foil powder such as titanium dioxide-coated mica or basic zinc carbonate, or the like is used. Moreover, you may add an inorganic filler as needed, and powders, such as calcium carbonate, barium sulfate, clay, talc, silica (silicon dioxide), and alumina (aluminum oxide), etc. are mentioned. The addition amount of the colorant is usually about 1 to 50 parts by weight with respect to 100 parts by weight of the resin material, but is not limited thereto.

  Moreover, each layer which comprises the decorating sheet 100 for shaping | molding can give easy-adhesion processes, such as a corona discharge process, a plasma process, and an ozone process.

"Method for manufacturing decorative molded products"
In addition, as a manufacturing method of the decorative molded product from which the decorative article which decorated this to-be-adhered body is obtained by shape | molding and laminating the sheet | seat for shaping | molding decoration of this invention to an to-be-adhered body, for example, Examples thereof include an injection molding simultaneous lamination method, a vacuum molding lamination method, and a lapping method. Moreover, when shape | molding the sheet | seat for shaping | molding decoration, it heats normally and performs after fully expressing the moldability by the thermoplastic resin part of each base material sheet.

  (1) Injection molding simultaneous lamination method: As described in Japanese Patent Publication No. Sho 50-19132, Japanese Patent Publication No. 43-27488, etc., the molding decorative sheet is disposed between both male and female molds of injection molding, This is a method in which a resin in a fluid state is injected and filled into a mold, and a molded decorative sheet is laminated on the surface simultaneously with the molding of a resin molding. In addition, this method is a method by a lamination | stacking form especially among the injection-molding simultaneous decorating methods which also have a transfer form etc.

  (2) Vacuum forming lamination method: as described in Japanese Patent Publication No. 56-45768 (overlay method), Japanese Patent Publication No. 60-58014 (vacuum press method), etc. This is a method in which a sheet for decorative decoration is opposed or placed on the surface of the substrate with an adhesive in between and the sheet for decorative decoration is laminated on the adherend by at least a pressure difference due to vacuum suction from the adherend side.

  (3) Lapping method: As described in Japanese Patent Publication No. 61-5895, Japanese Patent Publication No. 56-233771, etc., with respect to columnar adherends such as cylinders and polygonal columns, In the long axis direction, a plurality of sheets constituting the adherend are formed by a plurality of differently oriented rollers (including a case where an elastic roller is not used) while supplying a molding decorative sheet via an adhesive layer therebetween. In this method, the decorative sheet is laminated by sequentially pressing and adhering the decorative sheet to the side surface. Usually, the decorative sheet is folded while being heated and laminated.

  Next, in particular, the injection molding simultaneous lamination method will be described in detail. This method is also a method adopted as the injection molding simultaneous lamination method of the present invention.

  In the injection molding simultaneous lamination method, the molded decorative sheet receives heat pressure from the injection resin even when the molded decorative sheet is not preheated. Therefore, the injection molding simultaneous laminating method is suitable for both the form in which the preforming of the decorative sheet is performed and the form in which it is not performed. Moreover, the pre-heating of the molded decorative sheet may or may not be performed. In addition, at the time of preliminary molding, the molded decorative sheet is usually preheated.

  Of course, it is preferable to perform preliminary molding when the drawing of the decorative sheet is large. On the other hand, when there is little restriction | limiting of the shaping | molding decoration sheet | seat, you may shape | mold a shaping | molding decoration sheet | seat with the resin pressure and resin heat of the resin of the fluid state inject | emitted. At this time, if the drawing is shallow, the decorative sheet may be formed only by the resin pressure and resin heat of the resin in a fluid state that is filled in the mold at the same time as the resin injection without preforming. Further, even when the molded decorative sheet is molded by resin pressure and resin heat, the molded decorative sheet may be heated only using the resin heat of the injection resin and not preheated. In addition, the preforming of the molding decorative sheet is usually performed by using the injection mold as the vacuum mold, but before supplying the molding decorative sheet between the molds, another molding is performed outside the injection mold. Preliminary molding (offline preliminary molding) in which a decorative sheet is vacuum molded with a vacuum mold may be used. However, the pre-molding is preferably performed by using both the injection mold and the vacuum mold in that the decorative sheet can be laminated efficiently and accurately. However, when the preformed decorative sheet is manufactured in advance in another place, the preform is preferably in the form of off-line preforming. In the description of the present invention, vacuum forming includes vacuum / pressure forming.

  With reference to the conceptual diagram of FIG. 3, the injection molding simultaneous lamination method will be described in one form. In addition, the form demonstrated here is the form which heats and softens the sheet | seat for shaping | molding decoration between molds, pre-molds it by vacuum molding with an injection mold, and injects resin after mold clamping It is. Moreover, this form is a more preferable form when the drawing of the shaping | molding decoration sheet | seat is deep among the various combinations of the above-mentioned preforming of the shaping | molding decoration sheet | seat and preheating.

  First, as shown in FIG. 3A, the injection mold includes a mold (male mold) Ma having a runner and a gate (gate) communicating with the injection nozzle, and a suction hole 41 on the cavity surface. A pair of molds (female molds) Mb that also serves as a sheet preforming mold is used. These molds are made of metal such as iron or ceramics. In the mold open state, the decorative sheet 10 is supplied between both molds Ma and Mb, and the molded decorative sheet 10 is fixed to the mold Mb by pressing it with a sheet clamp 42 having a frame shape in plan view. In this case, the colored substrate sheet side (relative to the surface substrate sheet) is of course the injection resin side on the right side of the drawing. Next, as shown in FIG. 3B, the heater 43 that has been retracted at the retracted position outside the mold (in the drawing, above the mold) is appropriately moved and inserted between both molds, and the heater 43 forms the decorative sheet. Soften by heating. The heating is, for example, non-contact radiation heating, but may be conduction heating by contact. And it sucks from a suction hole and vacuum-forms, and the sheet | seat for shaping | molding decoration is preformed along the cavity surface of type | mold Mb. Next, the heater 43 is retracted from between both molds to the retreat position outside the mold, both molds are clamped as shown in FIG. 3C, and a resin in a fluid state such as a heat-melted state is placed in the cavity formed by both molds. Fill. Then, after the resin is solidified by cooling or the like, the mold is opened, the molded product is taken out, and if there is an unnecessary portion of the molded decorative sheet, trimming is appropriately performed to obtain a decorative molded product as a decorative article.

  In the above process, heat and pressure are applied to the decorative sheet at the time of preliminary molding and resin injection, whereby a thermoplastic resin is used for part of the surface base sheet and the colored base sheet. And sufficient moldability can be expressed in the sheet | seat for shaping | molding decoration, and the sheet | seat for shaping | molding decoration can be shape | molded.

  In addition, there is no restriction | limiting in particular as an adherend used as the lamination | stacking object of the sheet | seat for shaping | molding decoration of this invention. The material of the adherend is arbitrarily selected from resin, metal, wood, inorganic nonmetal, and the like. In addition, the shape of the adherend is arbitrary such as a plate shape (a flat plate or a curved plate), a column shape, a three-dimensional solid object, or the like as long as the molded decorative sheet can be laminated on the laminated surface. The material of the adherend is preferably a resin molded product.

  For example, as the resin, polyethylene, polypropylene, polybutene, polymethylpentene, ethylene-propylene copolymer, ethylene-propylene-butene copolymer, polyolefin resin such as olefin thermoplastic elastomer, ABS (acrylonitrile-butadiene-styrene copolymer). Polymer) Resin, styrene resin, vinyl chloride resin, acrylic resin, polycarbonate resin and other thermoplastic resins, two-component curable urethane resin, unsaturated polyester resin, epoxy resin and other curable resins. In addition, examples of metals include iron, aluminum, and copper, and examples of wood include veneer, plywood, particleboard, fiberboard, and laminated wood made of cedar, straw, firewood, lawan, teak, etc. Non-ceramic ceramic materials such as extruded cement, slag cement, ALC (lightweight cellular concrete), GRC (glass fiber reinforced concrete), pulp cement, wood chip cement, asbestos cement, calcium silicate, gypsum, gypsum slag, earthenware , Ceramics such as pottery, porcelain, setware, glass, glaze, and the like.

  The decorative sheet for molding according to the present embodiment has no polyester urethane resin layer, and of course can ensure adhesion more than the base sheet and the acrylic resin layer are in direct contact with each other. The resin layer can be suitably followed by the elongation generated during molding, and at the time of molding, the polyester urethane resin layer and other decorative sheet for molding (for example, if a decorative layer is provided) flow, deformation, It is possible to more suitably prevent the cutting or the like from occurring. By this prevention, it is possible to more suitably prevent the adhesive strength between the base sheet and the acrylic resin layer from being lowered due to flow, deformation, cutting, or the like.

  In the decorative sheet for molding produced as described below, when the resin is changed between the pattern layer and the base sheet and molded as a decorative molded product, the polyester urethane resin layer flows, deforms and breaks. It was visually evaluated whether or not adhesion could be prevented and whether or not the adhesion between the design layer and the substrate sheet could be secured.

Evaluation criteria are
"Crack prevention"
○: Good (there is almost no cracking observed)
X: Defect (recognized that cracking occurs).
"Adhesion"
○: Good (there is almost no peeling)
X: Defect (a peeling is recognized).

"Production method"
(Example) An acrylic resin ink containing an aluminum pigment is used on an acrylic film having a thickness of 125 μm, a pattern layer is formed by a gravure printing method, and then a polyester urethane adhesive is applied as a polyester urethane resin at a coating amount of 10 g / m. ² is applied to form a polyester urethane resin layer, a butadiene-containing 42% by weight ABS resin sheet having a thickness of 300 μm is laminated, and heat lamination is performed at a temperature of 85 ° C., a pressing force of 8 kg / cm ² , and a speed of 5 m / min. Thus, a decorative sheet for molding was obtained.

  The obtained decorative sheet was produced as a decorative article by decorating the surface of the resin molded product by the injection molding simultaneous lamination method. The shape of the molded product is an interior part around the shift gear of an automobile. The shape of the part is 18 cm wide and 30 cm long. To decorate the surface, the molded decorative sheet is stretched by about 150% (area ratio: the area is about 1.5 times after molding) and molded. It was a part that needed to be done.

(Comparative Example 1) An acrylic resin ink containing an aluminum pigment is used on an acrylic film having a thickness of 125 μm, a pattern layer is formed by a gravure printing method, and then a vinyl chloride-vinyl acetate copolymer adhesive is used as a vinyl resin. Is applied at a coating amount of 10 g / m ² to form a vinyl resin layer, a butadiene-containing 42 wt% ABS resin sheet having a thickness of 300 μm is laminated, a temperature of 85 ° C., a pressing force of 8 kg / cm ² , and a speed of 5 m. The decorative sheet for molding was obtained by heat lamination under the conditions of / min.

  The obtained decorative sheet was produced as a decorative article by decorating the surface of the resin molded product by the injection molding simultaneous lamination method. The shape of the molded product is an interior part around the shift gear of an automobile. The shape of the part is 18 cm wide and 30 cm long. To decorate the surface, the molded decorative sheet is stretched by about 150% (area ratio: the area is about 1.5 times after molding) and molded. It was a part that needed to be done.

(Comparative Example 2) On an acrylic film having a thickness of 125 μm, an acrylic resin ink containing an aluminum pigment was used, a pattern layer was formed by a gravure printing method, and then an acrylic adhesive was applied as an acrylic resin at a coating amount of 10 g / m. ² is applied to form an acrylic resin layer, a butadiene-containing 42% by weight ABS resin sheet having a thickness of 300 μm is laminated, and heat lamination is performed at a temperature of 85 ° C., a pressing force of 8 kg / cm ² , and a speed of 5 m / min. Thus, a decorative sheet for molding was obtained.

  The obtained decorative sheet was produced as a decorative article by decorating the surface of the resin molded product by the injection molding simultaneous lamination method. The shape of the molded product is an interior part around the shift gear of an automobile. The shape of the part is 18 cm wide and 30 cm long. To decorate the surface, the molded decorative sheet is stretched by about 150% (area ratio: the area is about 1.5 times after molding) and molded. It was a part that needed to be done.

"Discussion"
From Table 1, it is possible to ensure adhesion by using a polyurethane resin layer rather than direct contact between the base sheet and the acrylic resin layer, and the elongation that occurs during molding than a resin layer mainly composed of vinyl resin or acrylic resin. It is possible to follow more favorably, and at the time of molding, it is more likely that the polyester urethane resin layer or other decorative sheet for molding (for example, a decorative layer if a decorative layer is provided) will flow, deform, break, etc. It can prevent suitably. It can be seen that this prevention can more suitably prevent the adhesion strength between the base sheet and the acrylic resin layer from being lowered due to flow, deformation, cutting, and the like, and can ensure adhesion.

DESCRIPTION OF SYMBOLS 100 Decorative sheet for molding 10 Acrylic resin layer 15 Polyester urethane resin layer 18 Pattern layer 20 Base material sheet

Claims (5)

A decorative sheet for molding used for decorating a decorative molded product that is manufactured by being integrated with an adherend,
A base material sheet as a support,
An acrylic resin layer formed in an upper layer than the base sheet;
Between the base sheet and the acrylic resin layer, a pattern layer formed on at least one surface of the acrylic resin layer surface and the base sheet surface;
A decorative sheet for molding, comprising: a polyester urethane resin layer that is formed on a surface of the design layer and adheres to both the base sheet and the acrylic resin layer. The decorative sheet for molding according to claim 1,
The main component of the base sheet is a decorative sheet for molding which is a polypropylene resin or an ABS resin. A pattern layer forming step of forming a pattern layer on the acrylic resin;
A polyester urethane resin layer forming step of forming a polyester urethane resin layer on the acrylic resin and the design layer;
A base sheet forming step of forming a base sheet on the polyester urethane resin layer, and a method for producing a decorative sheet for molding. A method for producing a decorative molded product produced by integrating a resin in a fluid state with the decorative sheet for molding according to claim 1 or 2,
An insertion step of inserting the decorative sheet for molding into a cavity portion in a molding machine;
A filling step of filling the cavity with the fluidized resin after the insertion;
The manufacturing method of the decorative molded product including the integration process which solidifies the resin of the said fluid state to make a resin molded product, and integrates the said resin molded product and the said decorative sheet for a shaping | molding. It is a manufacturing method of the decorative molded product of Claim 4, Comprising:
The filling is a method of manufacturing a decorative molded product in which the fluid resin is injected and filled into the cavity.

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