JP2014151626A - Method for producing resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a resin molding having irregularities on the surface.SOLUTION: After an ultraviolet curing resin layer 120 is formed on a synthetic resin sheet 110, the ultraviolet curing resin layer 120 is irradiated with ultraviolet rays to the extent of not allowing an ultraviolet curing resin in the ultraviolet curing resin layer 120 to cure completely. Then after irregularities are formed on the incompletely cured ultraviolet curing resin layer 120, the ultraviolet curing resin layer 120 is irradiated further with ultraviolet rays to cure completely.

Description

  The present invention relates to a method for producing a resin molded product.

  Japanese Patent Application Laid-Open No. 2011-169987 describes an antiglare film obtained by curing an ultraviolet curable resin composition applied on a substrate. This anti-glare film is configured such that a concavo-convex surface is formed on a substrate, and an ultraviolet curable resin is made to follow the concavo-convex surface, thereby forming an undulation on the surface of the ultraviolet curable resin.

JP2011-169987A

  However, in the manufacturing process of the antiglare film described in JP2011-169987A, the ultraviolet curable resin is leveled, and it is difficult to form predetermined irregularities on the surface of the ultraviolet curable resin. is there. Then, this invention is made | formed in view of said problem, and it aims at providing the manufacturing method of the resin molded product in which the unevenness | corrugation was formed in the surface.

  In order to solve the above problems, according to a preferred embodiment of the method for producing a resin molded product according to the present invention, a base material preparing step for preparing a base material, and an ultraviolet curable resin arranging step for arranging an ultraviolet curable resin on the base material And a first ultraviolet irradiation step of irradiating the ultraviolet curable resin with ultraviolet rays to such an extent that the ultraviolet curable resin is not completely cured, an irregularity forming step for forming irregularities on the ultraviolet curable resin, and the ultraviolet curable resin is completely cured. And a second ultraviolet irradiation step of irradiating the ultraviolet curable resin with ultraviolet rays for causing the ultraviolet curable resin.

  According to the present invention, the ultraviolet curable resin can be cured to a predetermined hardness in the first ultraviolet irradiation step. As a result, the ultraviolet curable resin can be cured to such a hardness that irregularities can be reliably formed on the ultraviolet curable resin. Furthermore, the intensity | strength of the formed unevenness | corrugation is securable by having a 2nd ultraviolet irradiation step by fully hardening | curing a ultraviolet curable resin.

  According to another preferred embodiment of the method for producing a resin molded product according to the present invention, a base material preparing step for preparing a base material having an ultraviolet curable resin disposed on the surface thereof, and an ultraviolet ray that does not completely cure the ultraviolet curable resin. A first ultraviolet irradiation step for irradiating the ultraviolet curable resin, an irregularity forming step for forming irregularities on the ultraviolet curable resin, and an ultraviolet ray for completely curing the ultraviolet curable resin. A second ultraviolet irradiation step.

  According to the present invention, the ultraviolet curable resin can be cured to a predetermined hardness in the first ultraviolet irradiation step. As a result, the ultraviolet curable resin can be cured to such a hardness that irregularities can be reliably formed on the ultraviolet curable resin. Furthermore, by having the second ultraviolet irradiation step, the formed unevenness can be reliably formed by completely curing the ultraviolet curable resin.

  According to the further form of the manufacturing method of the resin molded product which concerns on this invention, it has the bending process step which bends a base material.

  According to this embodiment, the resin molded product can be processed into a predetermined shape by bending the substrate.

  According to the further form of the manufacturing method of the resin molded product which concerns on this invention, it has the bending process step which bends a base material. And a bending process step is performed between a base material preparation step and an ultraviolet curable resin arrangement | positioning step.

  According to this embodiment, the resin molded product can be processed into a predetermined shape by bending the substrate. Furthermore, since the bending step is performed before the ultraviolet curable resin arrangement step, the ultraviolet curable resin is not damaged in the bending process as compared with the configuration in which the base material is bent after the ultraviolet curable resin is arranged.

  According to the further form of the manufacturing method of the resin molded product which concerns on this invention, it has an ink layer formation step which forms an ink layer in the surface on the opposite side to the ultraviolet curable resin in a base material. The ink layer forming step is preferably performed before the first ultraviolet irradiation step.

  According to this embodiment, the ultraviolet curable resin can be reliably cured by irradiating the ultraviolet light from the side where the ultraviolet curable resin is disposed on the substrate.

  According to a preferred embodiment of the resin molded product according to the present invention, the unevenness forming step includes a step of arranging the base material so that the ultraviolet curable resin contacts the surface of the injection mold on which the unevenness for transfer is formed, and the injection molding Injection molding a molten resin onto the mold. Then, the unevenness for transfer formed on the surface of the injection mold is transferred to the ultraviolet curable resin to form the unevenness. Furthermore, this uneven | corrugated formation step is performed between the 1st ultraviolet irradiation step and the 2nd ultraviolet irradiation step.

  According to this embodiment, since the unevenness for transfer formed on the injection mold in the injection molding step is transferred to the ultraviolet curable resin, the unevenness formation on the ultraviolet curable resin and the injection molding can be performed simultaneously. As a result, the manufacturing process of the synthetic resin molded product can be simplified. In addition, since the unevenness forming step is performed between the first ultraviolet irradiation step and the second ultraviolet irradiation step, the hardness of the ultraviolet curable resin is set to a hardness at which the transfer unevenness is reliably transferred in the first ultraviolet irradiation step. can do.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the resin molded product for forming an unevenness | corrugation on the surface of ultraviolet curable resin can be provided.

It is a perspective view which shows the synthetic resin molded product 100 which concerns on this invention. It is sectional drawing in the II-II line of FIG. It is a figure which shows the 1st process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention. It is a figure which shows the 2nd process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention. It is a figure which shows the 3rd process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention. It is a figure which shows the 4th process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention. It is a figure which shows the 5th process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention. It is a figure which shows the 6th process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention. It is a figure which shows the 7th process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention. It is a figure which shows the 8th process of the manufacturing method of the synthetic resin molded product 100 which concerns on this invention.

  An embodiment of the present invention will be described with reference to FIGS. The present embodiment will be described using a synthetic resin molded product as an in-vehicle panel used for a vehicle speedometer or the like as an example of a resin molded product. As shown in FIG. 1, the synthetic resin molded product 100 is a backlit synthetic resin molded product in which numbers and patterns are visible. As shown in FIGS. 1 and 2, the synthetic resin molded product 100 is mainly composed of a synthetic resin sheet 110 and a molding resin 150. On the outer peripheral portion of the synthetic resin sheet 110, a predetermined convex portion 140 is formed as a design of the in-vehicle panel. Further, an ultraviolet curable resin layer 120 and a colored ink layer 130 are formed on the surface of the synthetic resin sheet 110. This synthetic resin molded product 100 is an implementation configuration example corresponding to the “resin molded product” in the present invention. Further, the synthetic resin sheet 110, the ultraviolet curable resin layer 120, and the colored ink layer 130 are implementation examples corresponding to the “substrate”, “ultraviolet curable resin”, and “ink layer” in the present invention, respectively.

  The synthetic resin sheet 110 is a flat plate-like transparent or translucent resin sheet, and is formed of PMMA (acrylic), PC (polycarbonate), PET (polyethylene terephthalate), PVC (vinyl chloride resin), or the like. It is configured as a single-layer or multi-layer sheet made of any one or more of these materials. The synthetic resin sheet 110 preferably has a thickness of 0.075 mm or more and 3 mm or less in consideration of forming the convex portion 140.

  The ultraviolet curable resin layer 120 is formed of an ultraviolet curable resin made of an acrylic, polyester, urethane, vinyl, fatty acid, epoxy, ester, or urethane acrylate material. In addition, an uneven pattern (not shown) such as embossing or embossing is formed on the surface of the ultraviolet curable resin layer 120. This uneven | corrugated pattern is the implementation structural example corresponding to the "unevenness | corrugation" in this invention.

  The colored ink layer 130 is an ink of acrylic type, polyester type, vinyl chloride type, acrylic urethane type or the like, and is black, white, red, blue, in accordance with the numbers, letters, and patterns displayed on the synthetic resin molded product 100. A plurality of layers of each color ink such as colorless are laminated. The colored ink layer 130 has a thickness of 4 μm or more.

  Next, with reference to FIGS. 3-10, the manufacturing method of the synthetic resin molded product 100 is demonstrated.

  As shown in FIG. 3, the first step is a step of preparing the synthetic resin sheet 110. In manufacturing the synthetic resin molded product 100, first, a synthetic resin sheet 110 as a base material is prepared. This 1st process is the implementation structural example corresponding to the "base material preparation step" in this invention.

  The second step is performed after the first step. As shown in FIG. 4, the second step is a step of forming the colored ink layer 130 on the surface of the synthetic resin sheet 110. Ink is applied to the surface of the synthetic resin sheet 110 by screen printing to form the colored ink layer 130. In order to make it possible to visually recognize numbers and patterns, the numbers and patterns are not coated with ink by masking. A plurality of colored ink layers 130 are formed by applying ink for each color to be colored. In the second step, in addition to screen printing, inkjet printing or other printing methods can be employed. This second step is an implementation configuration example corresponding to the “ink layer forming step” in the present invention.

  A third step is performed after the second step. As shown in FIG. 5, the third step is a step of forming the predetermined convex portion 140 by bending the synthetic resin sheet 110. The synthetic resin sheet 110 is formed (formed) into a predetermined shape by forming the convex portion 140 on the synthetic resin sheet 110 by a method such as vacuum molding, compressed air molding, or press molding. In the third step, an R attaching process in which the convex portion 140 is formed in an R shape is performed at the same time. This third step is an implementation configuration example corresponding to the “bending step” in the present invention.

  A fourth step is performed after the third step. As shown in FIG. 6, a 4th process cuts the synthetic resin sheet 110 formed in the predetermined | prescribed shape, and the some synthetic resin piece 110a is formed. This fourth step can be omitted. That is, after the synthetic resin sheet 110 is formed in a predetermined shape, the synthetic resin sheet 110 may be used in subsequent steps without being cut off.

  The fifth step is performed after the fourth step. As shown in FIG. 7, the fifth step is a step of forming the ultraviolet curable resin layer 120. The ultraviolet curable resin layer 120 is formed by coating an ultraviolet curable resin on the surface of the synthetic resin sheet 110 opposite to the surface on which the colored ink layer 130 is formed. At this time, an ultraviolet curable resin is applied to each synthetic resin piece 110a. This fifth step is an implementation configuration example corresponding to the “ultraviolet curable resin arrangement step” in the present invention.

  The sixth step is performed after the fifth step. As shown in FIG. 8, the sixth step is a step of curing the ultraviolet curable resin layer 120. In the sixth step, the irradiation intensity and irradiation time of the ultraviolet rays irradiated from the ultraviolet irradiation lamp 300 are controlled so that the ultraviolet curable resin is not completely cured. Thereby, before forming an unevenness | corrugation with respect to the ultraviolet curable resin layer 120, the hardness of the ultraviolet curable resin layer 120 can be set suitably. This sixth step is an implementation configuration example corresponding to the “first ultraviolet irradiation step” in the present invention.

  The seventh step is performed after the sixth step. As shown in FIG. 9, the seventh step is a step of performing insert molding on the synthetic resin sheet 110. The molding die 200 is formed by an upper die 201 and a lower die 202. An uneven pattern such as a texture is formed on the inner surface of the upper mold 201. The synthetic resin sheet 110 (synthetic resin piece 110a) is arranged so that the ultraviolet curable resin layer 120 of the synthetic resin sheet 110 contacts the surface of the upper mold 201. Thereafter, the upper mold 201 and the lower mold 202 are connected, pressure is applied to the molten resin, and the molten resin is poured into the mold 200 to perform insert molding. As the molten resin solidifies, the molding resin 150 is integrally bonded to the synthetic resin sheet 110. At this time, the uneven pattern formed on the inner surface of the upper mold 201 is transferred to the ultraviolet curable resin layer 120. This seventh step is an implementation configuration example corresponding to the “unevenness forming step” in the present invention.

  The eighth step is performed after the seventh step. As shown in FIG. 10, the eighth step is a step of curing the ultraviolet curable resin layer 120. In the eighth step, the irradiation intensity and irradiation time of the ultraviolet rays irradiated from the ultraviolet irradiation lamp 300 are controlled so that the ultraviolet curable resin is completely cured. As an example, the irradiation intensity is made stronger than the ultraviolet irradiation intensity in the sixth step. As a result, the ultraviolet curable resin layer 120 on which the irregularities are formed is completely cured. The eighth step is an implementation configuration example corresponding to the “second ultraviolet irradiation step” in the present invention.

  In the above embodiment, the first step, the fifth step, the sixth step, the seventh step, and the eighth step can be used in appropriate combination with the second to fourth steps.

  According to the above embodiment, the ultraviolet curable resin layer 120 in which the unevenness is formed by having the sixth step of irradiating the ultraviolet curable resin layer 120 with ultraviolet rays before transferring the unevenness to the ultraviolet curable resin layer 120. The hardness can be set as appropriate. Therefore, by setting the ultraviolet curable resin layer 120 to a hardness at which the unevenness is easily transferred, the unevenness is reliably transferred to the surface of the ultraviolet curable resin layer 120. Moreover, the intensity | strength of an unevenness | corrugation is securable by having the 8th process which hardens | cures the ultraviolet curing resin layer 120 to which the unevenness | corrugation was transferred completely.

  Moreover, according to this embodiment, since the 3rd process of bending a base material is performed before the 5th process which arrange | positions ultraviolet curable resin, damage arises in the ultraviolet curable resin layer 120 by bending a base material. This can be prevented.

  Further, according to the present embodiment, the irregularities can be transferred to the ultraviolet curable resin layer 120 in the seventh step of insert molding. That is, the manufacturing process of the synthetic resin molded product 100 can be simplified by simultaneously performing the insert molding and transferring the unevenness to the surface of the ultraviolet curable resin layer.

  In the above embodiment, the ultraviolet curable resin layer 120 is formed on the surface of the synthetic resin sheet 110 opposite to the surface on which the colored ink layer 130 is formed in the fifth step. However, the present invention is not limited to this. . For example, the ultraviolet curable resin layer 120 may be formed on the surface of the colored ink layer 130.

  Next, a modified example in which this embodiment is modified will be described. In the above embodiment, the synthetic resin sheet 110 is prepared in the first step, and the ultraviolet curable resin layer 120 is disposed on the surface of the synthetic resin sheet 110 in the fifth step. A synthetic resin sheet in which the synthetic resin sheet 110 and the uncured ultraviolet curable resin layer 120 are integrally formed is prepared. In this modification, the fifth step can be omitted.

  Also in the above modification, there exists an effect similar to said embodiment. In the above modification, the first step, the sixth step, the seventh step, and the eighth step can be used in appropriate combination with the second to fourth steps.

  In the above, the colored ink layer 130 is formed on one surface of the synthetic resin sheet 110 in the second step, but the present invention is not limited to this. For example, the second step may not be provided. Further, the ultraviolet curable resin layer 120 may be a colored resin. On the other hand, in the second step, the colored ink layer 130 may be formed on both surfaces of the synthetic resin sheet 110.

  Moreover, in the above, although the 7th process which performs a bending process with respect to the synthetic resin molded product 100 was provided, it does not need to have a 7th process. Further, the bending process is not limited to hot working, and cold working may be employed.

(Correspondence between each component of the embodiment and each component of the present invention)
The correspondence between each component of the above embodiment and each component of the present invention is shown as follows. In addition, embodiment shows an example of the form for implementing this invention, and this invention is not limited to the structure of embodiment.
The synthetic resin molded product 100 is an example of a configuration corresponding to the “resin molded product” of the present invention.
The synthetic resin sheet 110 is an example of a configuration corresponding to the “base material” of the present invention.
The ultraviolet curable resin layer 120 is an example of a configuration corresponding to the “ultraviolet curable resin” of the present invention.
The colored ink layer 130 is an example of a configuration corresponding to the “ink layer” of the present invention.
The ultraviolet curable resin layer 120 is an example of a configuration corresponding to the “ultraviolet curable resin” of the present invention.
The mold 200 is an example of a configuration corresponding to the “injection mold” of the present invention.
The first step is an example of a configuration corresponding to the “resin sheet preparation step” of the present invention.
The second step is an example of a configuration corresponding to the “ink layer forming step” of the present invention.
The third step is an example of a configuration corresponding to the “bending step” of the present invention.
The fifth step is an example of a configuration corresponding to the “ultraviolet curable resin arrangement step” of the present invention.
The sixth step is an example of a configuration corresponding to the “first ultraviolet irradiation step” of the present invention.
The seventh step is an example of a configuration corresponding to the “unevenness forming step” of the present invention.
The eighth step is an example of a configuration corresponding to the “second ultraviolet irradiation step” of the present invention.

100 Synthetic resin molded product 110 Synthetic resin sheet 110a Synthetic resin piece 120 UV curable resin layer 130 Colored ink layer 140 Convex part 200 Mold 201 Upper mold 202 Lower mold 300 UV irradiation lamp

Claims (7)

A method for producing a resin molded article having irregularities on the surface,
A substrate preparation step of preparing a substrate;
An ultraviolet curable resin arrangement step of arranging an ultraviolet curable resin on the substrate;
A first ultraviolet irradiation step of irradiating the ultraviolet curable resin with an ultraviolet ray such that the ultraviolet curable resin is not completely cured;
Concavity and convexity forming step for forming concavities and convexities on the ultraviolet curable resin,
And a second ultraviolet irradiation step for irradiating the ultraviolet curable resin with ultraviolet rays for completely curing the ultraviolet curable resin. A method for producing a resin molded article having irregularities on the surface,
A base material preparation step for preparing a base material on which UV curable resin is disposed on the surface;
A first ultraviolet irradiation step of irradiating the ultraviolet curable resin with an ultraviolet ray such that the ultraviolet curable resin is not completely cured;
Concavity and convexity forming step for forming concavities and convexities on the ultraviolet curable resin,
And a second ultraviolet irradiation step for irradiating the ultraviolet curable resin with ultraviolet rays for completely curing the ultraviolet curable resin. A method for producing a resin molded product according to claim 1 or 2,
A method for producing a resin molded product comprising a bending step of bending the base material. It is a manufacturing method of the resin molded product according to claim 1,
A bending step of bending the substrate;
The method for producing a resin molded product, wherein the bending step is performed between the base material preparation step and the ultraviolet curable resin arrangement step. A method for producing a resin molded product according to any one of claims 1 to 4,
A method for producing a resin molded product, comprising: an ink layer forming step of forming an ink layer on a surface of the substrate opposite to the ultraviolet curable resin. It is a manufacturing method of the resin molded product according to claim 5,
The method for producing a resin molded product, wherein the ink layer forming step is performed before the first ultraviolet irradiation step. A method for producing a resin molded product according to any one of claims 1 to 6,
The unevenness forming step includes
Arranging the base material so that the ultraviolet curable resin is in contact with the surface of the injection mold on which the unevenness for transfer is formed;
A step of injection-molding a molten resin to the injection mold, and the unevenness for transfer formed on the surface of the injection mold is transferred to the ultraviolet curable resin so that the unevenness is formed. Is composed of
The unevenness forming step is performed between the first ultraviolet irradiation step and the second ultraviolet irradiation step.

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