JP2017007309A - Method for manufacturing decorative molded article, and preform molded article for decorative molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative molded article which prevents an uneven surface such as an embossed pattern from disappearing and prevents a depth of a recess from making shallow, and has a grained artificial leather having an even surface keeping its three-dimensional feeling on a surface layer.SOLUTION: A method for manufacturing a decorative molded article includes: a step of forming a surface resin layer on an uneven surface of a releasable resin sheet having the uneven surface, layering a fiber base material including a non fabric cloth made of an ultrafine fiber on the surface resin layer, and forming an artificial leather with a releasable resin sheet; a step of molding a preform molded article of the artificial leather with the releasable resin sheet; a step of arranging the preform molded article in a cavity of a mold, injecting a molten resin to the side of the fiber base material of the preform molded article, and molding an in-mold molded article; and a step of peeling the releasable resin sheet from the in-mold molded article and thereby obtaining a decorative molded article.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a decorative molded body having an artificial leather-like appearance, and more specifically, an artificial leather-like appearance by placing a preform molded article of artificial leather in a cavity of a mold and performing in-mold injection molding. The present invention relates to a method for producing a decorative molded body having the following.

  BACKGROUND ART A decorative molded body having artificial leather on the surface is known as an exterior member for interior parts such as vehicles and aircraft, mobile phones, mobile devices, housings for home appliances, building materials, and furniture. The decorative molded body with artificial leather on the surface is known to have a decorative surface with silver-coated artificial leather that has a cushioning property by a fiber base material and is laminated with a resin layer resembling the silver surface of leather. It has been.

  For example, in Patent Document 1 below, a reinforcing sheet having a thickness of 0.1 to 0.6 mm is bonded to the back of an artificial leather made of fibers having a fineness of 0.05 denier or more and having a thickness of 0.4 to 1.0 mm. The insert material having a feeling of feeling with silver is made into a three-dimensional shape by pre-molding, punched into the required shape and stored in the cavity in the injection mold, and then molded resin in the molten state from the reinforcing sheet side of the insert material A method for producing a molded product in which artificial leather obtained by integrating a insert material on the surface of a resin molded product having a thickness of at least 0.2 mm by molding is molded on the surface is disclosed.

By the way, although not related to artificial leather, Patent Document 2 below is a resin decorative film for imparting a concavo-convex pattern to the surface of a molded product in film insert molding,
Disclosed is a decorative film for film insert molding comprising a shaping layer film provided with a concavo-convex pattern and a protective layer film in close contact with the concavo-convex pattern, wherein the shaping layer film and the protective layer film are weakly bonded.

Japanese Patent Application Laid-Open No. 2006-281592 JP 2013-43417 A

  Three-dimensional embossing unevenness may be formed on the resin layer of the surface layer of silver-finished artificial leather by embossing embossing or embossing paper to improve decoration. It was. When a decorative molded body having a three-dimensional embossed unevenness on the surface is manufactured by a method as disclosed in Patent Document 1, heat transmitted from a molten resin at the time of injection molding or a mold Due to the mold temperature, the decorative surface softens and the surface resin layer stretches and the three-dimensional embossed unevenness disappears, or the depth of the recessed portion becomes shallow, and the three-dimensional tactile sensation is lost or lowered. There was a problem of doing.

  The present invention suppresses the disappearance of an uneven surface such as an embossed pattern or the depth of a concave portion, and the surface layer of artificial leather with a silver tone having unevenness with a three-dimensional tactile sensation maintained. It aims at providing the decorative molded object which has.

  One aspect of the present invention is to form a release resin by forming a surface resin layer on the uneven surface of a releasable resin sheet having an uneven surface, and further laminating a fiber substrate containing a nonwoven fabric of ultrafine fibers on the surface resin layer. A process for forming artificial leather with a sheet, a process for forming a preform molded body of artificial leather with a releasable resin sheet, a preform molded body placed in a cavity of a mold, and fibers of the preform molded body A decorative molded body comprising: a step of injecting a molten resin onto a substrate side to form an in-mold molded body; and a step of obtaining a decorative molded body by peeling the release resin sheet from the in-mold molded body. It is a manufacturing method. In such a manufacturing method, the unevenness of the three-dimensional embossed surface of the silver-finished artificial leather is eliminated or the depth of the recesses is reduced by heat transmitted from the mold surface during injection molding during in-mold injection molding. Is suppressed. As a result, a decorative molded body having an artificial leather having unevenness like an embossed pattern excellent in three-dimensional tactile sensation on the surface layer is obtained.

  The releasable resin sheet preferably has a laminated structure in which a polyolefin resin sheet is laminated on a polyester resin sheet.

  In another aspect of the present invention, a release resin sheet is provided by sequentially laminating a fiber substrate including a surface resin layer and a nonwoven fabric of ultrafine fibers on the uneven surface of a release resin sheet having an uneven surface. This is a decorative molded preform for decorative molding obtained by shaping a three-dimensional shape on artificial leather.

  ADVANTAGE OF THE INVENTION According to this invention, the decoration molded body which has the artificial leather provided with the resin layer which hold | maintained the three-dimensional unevenness | corrugation like an embossed surface on the surface layer is obtained.

Drawing 1 is an explanatory view showing each process for manufacturing artificial leather with a releasable resin sheet. FIG. 2 is a schematic cross-sectional view illustrating each step of preform molding. FIG. 3 is a schematic cross-sectional view illustrating each process of in-mold molding. FIG. 4 is a schematic cross-sectional view of the decorative molded body 40 whose decorative surface is exposed.

  In the method for producing a decorative molded body according to this embodiment, a surface resin layer is formed on the concavo-convex surface of a releasable resin sheet having an concavo-convex surface, and a fiber base material including a nonwoven fabric of ultrafine fibers is further laminated on the surface resin layer. And forming the artificial leather with a releasable resin sheet, forming the preform into an artificial leather with a releasable resin sheet, and placing the preform in the mold cavity. Arranging the molded molded body by injecting molten resin to the fiber substrate side of the preform molded body and molding the in-mold molded body, and removing the releasable resin sheet from the in-mold molded body And a process for obtaining a decorative molded body.

  First, a method for producing an artificial leather with a releasable resin sheet used in the method for producing a decorative molded body of the present embodiment will be described in detail with reference to FIG.

  Drawing 1 is an explanatory view showing each process for manufacturing artificial leather with a releasable resin sheet used with a manufacturing method of a decoration fabrication object of this embodiment. In FIG. 1, 1 is a fiber substrate including a nonwoven fabric of ultrafine fibers, 2 is a resin layer having an uneven surface, 2a is an uncured resin, 3 is artificial leather, and 4 is a release resin sheet having an uneven surface. As the releasable resin sheet 4, for example, an embossed sheet formed by pressing a sheet having an uneven surface 4 a on a resin sheet 4 b serving as a base material is used.

  In the method for producing the artificial leather with a releasable resin sheet, as shown in FIG. 1 (a), for example, a releasable resin sheet 4 having a textured uneven surface is prepared. And as shown in FIG.1 (b), the uncured resin 2a of polymeric elastic bodies, such as a polyurethane, is apply | coated to the uneven | corrugated surface of the release resin sheet 4. FIG. Then, by curing the uncured resin 2a by heating or the like, as shown in FIG. 1C, the resin layer 2 having an embossed uneven surface is formed. And an adhesive agent is apply | coated to the resin layer 2 on a releasable resin sheet, the fiber base material 1 is bonded together, it presses and adheres as needed, and a fiber base as shown in FIG.1 (d) is shown. A mold release comprising: an artificial leather 3 including a silver-tone resin layer 2 having an uneven surface laminated on one surface of a material 1 and a fiber base material 1; and a releasable resin sheet 4 laminated on the artificial leather 3. A synthetic resin sheet-containing artificial leather 10 is obtained.

  Next, the material used for manufacture of the artificial leather with a releasable resin sheet will be described in detail.

  The fiber substrate preferably includes a non-woven fabric of ultrafine fibers having a fineness of 1 dtex or less. The nonwoven fabric of ultrafine fibers preferably contains ultrafine fibers having a fineness of 1 dtex or less, more preferably 0.01 to 0.8 dtex, particularly 0.05 to 0.5 dtex, especially 0.07 to 0.1 dtex. . When the fineness of the ultrafine fibers is too high, when the artificial leather with a releasable resin sheet is preform-formed, the stretchability during softening by heating tends to decrease, and the formability tends to decrease. Moreover, when the fineness is too low, the industrial productivity of the nonwoven fabric tends to decrease.

The apparent density of the ultrafine fiber nonwoven fabric is 0.45 g / cm ³ or more, more preferably 0.45 to 0.70 g / cm ³ , and particularly preferably 0.50 to 0.65 g / cm ³ . When the nonwoven fabric has such a high apparent density, it is difficult to cause the molten resin to reach the resin layer that is the decorative surface in in-mold molding, and it is easy to obtain a decorative molded body that retains voids in the nonwoven fabric. As a result, the influence of heat on the concavo-convex surface is suppressed, so that the embossed concavo-convex surface is eliminated or the depth of the concave portion is reduced. The apparent density of the nonwoven fabric is, for example, the value of the basis weight measured by the method described in JIS L 1096 8.4.2 (1999) as the thickness value measured at a load of 240 gf / cm ² according to JIS L1096. It can be calculated by dividing.

  In order to make the nonwoven fabric have such a high apparent density, the ultrafine fiber is a fiber formed by converging a plurality of ultrafine single fibers that are formed through ultrafine fiber forming fibers such as sea-island type composite fibers. It is preferably present as a bundle. Specifically, for example, it is preferable that 5 to 1000, more preferably 5 to 200, particularly preferably 10 to 50, and most preferably 10 to 30 ultrafine fibers are present as a fiber bundle. Thus, when the ultrafine fibers are present in the form of fiber bundles, the apparent density of the nonwoven fabric can be increased.

Specific examples of the resin component forming the ultrafine fiber include, for example, polyethylene terephthalate (PET), modified polyethylene terephthalate, polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polytriethylene terephthalate, polyhexamethylene terephthalate, Aromatic polyester resins such as polypropylene terephthalate and polyethylene naphthalate; aliphatic polyesters such as polylactic acid, polyethylene succinate, polybutylene succinate, polybutylene succinate adipate, and polyhydroxybutyrate-polyhydroxyvalerate copolymer Resins such as polyamide 6, polyamide 66, polyamide 610, polyamide 10, polyamide 11, polyamide 12, polyamide 6-12 -Based resins; polyolefin resins such as polypropylene, polyethylene, polybutene, polymethylpentene, chlorinated polyolefin, ethylene vinyl acetate copolymer, styrene ethylene copolymer; modified polyvinyl alcohol containing 25 to 70 mol% of ethylene units, etc. And modified elastomers such as polyurethane elastomers, polyamide elastomers, and polyester elastomers. Among these, polyesters having a glass transition temperature (T _g ) of 100 to 120 ° C., more preferably 105 to 115 ° C. are preferred from the viewpoint of excellent shapeability during preform molding. In the case of preform molding, if the _Tg is too high, the stretchability of the fiber tends to decrease and the formability tends to decrease. If the _Tg is too low, it becomes too soft and solidifies. There is a tendency to take. As the polyester a T _g is 100 to 120 ° C., aromatic polyethylene terephthalate disturb the structure of the linear to the structural unit copolymerizable component modified polyethylene terephthalate containing, as a constituent unit, in particular, isophthalic acid, phthalic acid, 5 A modified polyethylene terephthalate containing an asymmetric aromatic carboxylic acid such as sodium sulfoisophthalic acid or an aliphatic dicarboxylic acid such as adipic acid as a copolymerization component in a predetermined ratio is preferable. More specifically, modified polyethylene terephthalate containing 2 to 12 mol% of isophthalic acid unit as a monomer component is preferable. T _g is measured by fixing a test piece having a width of 5 mm and a length of 30 mm between chucks with a spacing of 20 mm using, for example, a dynamic viscoelasticity measuring apparatus (for example, FT Leospectra DDVIV manufactured by Rheology). It can be obtained by measuring the dynamic viscoelastic behavior under conditions of a region of 30 to 250 ° C., a temperature rising rate of 3 ° C./min, a strain of 5 μm / 20 mm, and a measurement frequency of 10 Hz.

  The fiber length of the ultrafine fiber is not particularly limited, but a long fiber is particularly preferable from the viewpoint of easily increasing the apparent density. Here, the long fiber means that it is not a short fiber cut by a predetermined length. The length of the long fibers is preferably 100 mm or more, and more preferably 200 mm or more from the viewpoint that the fiber density of the ultrafine fibers can be sufficiently increased. When the length of the ultrafine fiber is too short, it tends to be difficult to increase the density of the fiber. Although an upper limit is not specifically limited, For example, the fiber length of several m, several hundreds m, several km or more spun continuously may be sufficient. Further, these fibers may be mixed with several kinds of fibers instead of single.

  Moreover, it is preferable that the nonwoven fabric containing an ultrafine fiber contains the polymer elastic body impregnated. Such a polymer elastic body improves the shape stability of the preform molded body. Specific examples of such a polymer elastic body include polyurethane, acrylonitrile elastomer, olefin elastomer, polyester elastomer, polyamide elastomer, acrylic elastomer, and the like. Of these, polyurethane, particularly crosslinked non-foamed polyurethane is preferred. The cross-linked non-foamed polyurethane suppresses deformation due to elastic recovery after release from the mold when preforming. As a result, when forming a deep-drawn preform, it is preferable because a sharp and sharp corner can be formed.

  The crosslinked non-foamed polyurethane is preferably formed using an aqueous emulsion of a crosslinkable polyurethane. Specific examples of the water-based emulsion of the crosslinkable polyurethane include water-based emulsions of polycarbonate-based polyurethane, polyester-based polyurethane, polyether-based polyurethane, and polycarbonate / ether-based polyurethane that form a crosslinked structure after drying.

The crosslinked non-foamed polyurethane is a cross-linked non-foamed polyurethane having a mass reduction rate of 5% by mass or less, preferably 3% by mass or less with respect to DMF immersion. It is preferable from the point that the deformation due to the elastic recovery is suppressed. In addition, the mass reduction | decrease rate with respect to DMF immersion of the bridge | crosslinking non-foaming polyurethane is after immersing in DMF 100 times the mass of polyurethane for 24 hours at normal temperature, DMF is filtered, the obtained filtrate is dried, and the mass Measure. And the following formula:
Mass reduction rate (%) = (1-weight after DMF immersion / weight before DMF immersion) × 100.

  Preform molding in which the content of the polymer elastic body in the nonwoven fabric is in the range of 5 to 40% by mass, more preferably 8 to 35% by mass, and particularly 12 to 30% by mass with respect to the total amount of the nonwoven fabric. From the point which is excellent in the formability of.

  The thickness of the nonwoven fabric is preferably about 200 to 800 μm, particularly about 300 to 600 μm. When the nonwoven fabric is too thin, the cushioning property is deteriorated, heat from the injection resin is easily transmitted to the resin layer, the embossed uneven surface is lost, and the depth of the recessed portion is reduced. When the nonwoven fabric is too thick, the decorative molded body tends to be too thick.

  As the polymer elastic body for forming the resin layer, polyurethane, an acrylic elastic body, a silicone elastic body, and the like conventionally used for forming a silver-tone resin layer can be used. The thickness of the resin layer is not particularly limited, but is preferably about 60 to 200 μm from the viewpoint that the balance between mechanical properties and texture can be maintained.

  The releasable resin sheet is not particularly limited as long as it is a thermoplastic easily peelable resin sheet that deforms along the shape of the mold in preform molding and is easily stretched by in-mold molding. As specific examples of such a resin sheet, a polyolefin sheet mainly composed of polyethylene or polypropylene, a sheet obtained by laminating a polyolefin sheet on a polyester resin sheet such as a PET sheet, particularly the following sheet is preferably used. .

  As a preferable example of the releasable resin sheet having a concavo-convex surface, for example, a polyolefin resin sheet is pressed and pressed against a smooth resin sheet such as a polyester resin sheet such as a PET sheet while forming concavo-convex on an polyolefin resin sheet. And a sheet that can be obtained by a method of cooling after bonding. In addition, in consideration of releasability, the uneven surface may be subjected to a releasability imparting treatment with a release agent such as silicone or fluorine.

  The thickness of the releasable resin sheet is preferably 50 to 1000 μm, more preferably 150 to 800 μm, and particularly preferably about 250 to 650 μm. If the releasable resin sheet is too thick, the moldability of preform molding tends to decrease, and if the releasable resin sheet is too thin, the effect tends to be insufficient.

  The decorative surface, which is an embossed uneven surface, is protected by a releasable resin sheet so as to fill the recessed portion of the uneven surface. Since the uneven surface which is a decorative surface is protected by such a releasable resin sheet, it is possible to suppress the uneven surface from being lost or the depth of the recessed portion to be reduced during in-mold molding. That is, since the concave portion of the concavo-convex surface is in close contact with the releasable resin sheet, the concave portion is supported, and the concavo-convex portion is not easily lost even by heat during injection molding.

  The total thickness of the artificial leather with the release resin sheet peeled off in this embodiment is preferably 300 to 1300 μm, more preferably 400 to 1200 μm, and particularly preferably about 600 to 1100 μm. If the overall thickness is too thin, the recesses tend to disappear or become shallow.

  And the preform molded object used with the manufacturing method of the decorative molded object of this embodiment is manufactured by hot press-molding the artificial leather with a release resin sheet | seat as mentioned above to a three-dimensional shape.

  With reference to FIG. 2, the process of preform-molding the artificial leather with a releasable resin sheet will be described. In the preform molding, first, as shown in FIG. 2A, the release resin sheet 4 is separated between the upper mold 7a and the lower mold 7b so as to face the lower mold 7b. The artificial leather 10 with moldable resin sheet is placed, and the artificial leather 10 with moldable resin sheet is softened by heating. And as shown in FIG.2 (b), the upper metal mold | die 7a and the lower metal mold | die 7b are clamped, and it shape | molds to the artificial leather 10 with a release resin sheet. And the intermediate molded object 21 of a preform molded object is formed by cooling.

  Then, as shown in FIG. 2 (c), the intermediate mold 21 is released by opening the upper mold 7a and the lower mold 7b. In this way, the intermediate molded body 21 is taken out.

  Although such an intermediate molded body 21 may be used as a preform molded body as it is, it is preferable to finish the preform molded body 20 that has been trimmed in advance by trimming and removing unnecessary portions. When the preform molded body is trimmed in advance and molded so as to form the contour of the decorative molded body, the contour of the decorative molded body obtained is obtained as in the case of trimming after injection molding. A cut surface is not formed on the end face, and a highly wear-resistant resin formed by injection molding is preferable from the viewpoint of forming the end face. In addition, when the decorative molded body is trimmed after injection molding, a cut surface of artificial leather usually appears on the end surface. In such a case, since the material having low wear resistance such as the fibers forming the artificial leather and the polymer elastic body appears on the end face, the wear resistance of the end face tends to be lowered. As shown in FIG. 2D, by trimming and removing unnecessary portions, a preform 20 that has been trimmed in advance is obtained.

  Next, with reference to FIG. 3, about the process of shape | molding the decoration molded body which equips the surface layer with the artificial leather of the silvery tone which has an uneven surface by in-mold molding by injection molding using a preform molded body. explain.

  As shown in FIG. 3A, the mold 17 includes a movable mold 17a including a cavity C and a fixed mold 17b. A stripper plate 17c is disposed between the movable mold 17a and the fixed mold 17b. First, the preform 20 of the artificial leather 10 with a releasable resin sheet having an embossed uneven surface protected by the releasable resin sheet 4 is formed on the movable side where the releasable resin sheet 4 forms a cavity C. It arrange | positions so that the surface of the metal mold | die 17a may be faced.

  The method for disposing the preform molded body inside the cavity is not particularly limited, but it is preferable that the preform molded body is fixed inside the cavity for positioning. When the preform molded body is not fixed inside the cavity, the preform molded body may be displaced in the cavity due to the flow of the injection resin at the time of injection molding in the next step. Specific examples of the method of fixing the preform molded body inside the cavity include, for example, a method of fixing to the surface of the movable mold with an adhesive, a hole or a recess included in the shape of the preform molded body. Can be fixed by fitting it in the core of the movable mold that matches the shape.

  And as shown in FIG.3 (b), by inject | pouring the molten resin 31a to the back surface side with respect to the surface where the mold release resin sheet of the preform molded object 20 in the metal mold | die 17 was arrange | positioned by injection molding. An in-mold molded body in which the foam molded body 20 is integrated on the surface is molded. Specifically, the movable mold 17a and the fixed mold 17b are clamped, and the cylinder 18 of the injection molding machine 15 is advanced until the nozzle 16 contacts the sprue bush 17f of the fixed mold 17b. The molten resin 31a melted in the cylinder 18 is injected with the screw 19, whereby the molten resin 31a is injected into the mold 17 and injection molded. The injected molten resin 31a flows through the resin flow path R in the mold 17 and flows into the cavity C to be filled. At this time, since the molten resin 31a permeates moderately into the fiber base material 1 including the nonwoven fabric of ultrafine fibers forming the artificial leather 3, the injection molded body 31 formed by injection molding maintains high adhesiveness due to the anchoring effect. Thus, it is integrated with the preform 20.

  Examples of the resin for molding an injection molded body that is injected by in-mold injection molding include polyolefin resins such as ABS resin, polycarbonate resin, and polypropylene, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). Various thermoplastic resins such as polyester resins and various polyamide resins are used without particular limitation, and are appropriately selected according to applications. For example, as a resin used for a casing of a mobile phone, a mobile device, a home appliance, etc., a resin having excellent impact resistance such as an ABS resin, a polycarbonate resin, and a polyolefin resin such as polypropylene is preferably used.

  The injection molding conditions are such that the resin can flow to the flow end depending on the melting point and melt viscosity of the resin to be injected, the shape of the molded body, and the resin thickness (resin temperature, mold temperature, injection pressure, injection speed, injection) The subsequent holding pressure and cooling time) are appropriately selected.

  And after completion | finish of injection, as shown in FIG.3 (c), the molten resin 31a is cooled, the injection molded body 31 is formed, and the in-mold molded body 30 with which the preform molded body 20 was integrated is shape | molded. . Then, as shown in FIG. 3D, by opening the mold 17, the movable mold 17a and the fixed mold 17b are isolated, and the runner 32 and the in-mold molded body 30 are taken out. . In this way, an in-mold molded body 30 having an embossed uneven surface protected by the releasable resin sheet 4 is obtained.

  Then, as shown in FIG. 4, the artificial leather-like uneven surface is exposed by peeling the release resin sheet 4 from the in-mold molded body 30 protected by the release resin sheet 4. A molded body 40 is obtained. The peeling method of the releasable resin sheet is not particularly limited, and is not particularly defined such as peeling by hand or peeling using a dedicated peeling equipment.

  Hereinafter, the present invention will be described more specifically with reference to examples. In addition, this invention is not limited at all by the Example.

[Example]
A releasable resin sheet having an uneven surface with a textured embossed depth of about 20 μm was prepared. The releasable resin sheet is formed by laminating and integrating a 50 μm thick polyolefin sheet on a 200 μm thick PET sheet and pressing the embossing roll from the polyolefin sheet side to form irregularities. It is a 250 μm sheet.

  Then, a polycarbonate non-yellowing type polyurethane resin solution was applied to the uneven surface of the releasable resin sheet, and dried at 80 ° C. for 10 minutes to form a polyurethane film having a thickness of 30 μm. Then, a polycarbonate-based non-yellowing type two-component curable polyurethane solution containing a colorant was further applied to the surface of the formed polyurethane film, and dried at 50 ° C. for 3 minutes to form a 120 μm-thick polyurethane film. . In this way, a silver-tone resin layer having a total thickness of 150 μm was formed on the uneven surface of the releasable resin sheet.

On the other hand, an apparent density of 0 entangled fiber bundles (average 25 fibers / bundle) of ultrafine fibers having a single fiber fineness of 0.08 dtex obtained by removing sea components from the nonwoven fabric of long sea-island composite fibers is 0. A fiber substrate having a thickness of 500 μm was prepared by impregnating a non-foamed polyurethane having a mass reduction rate of 0.5 mass% with respect to DMF soaking into a nonwoven fabric of .53 g / cm ³ . The ultrafine fiber was made of an isophthalic acid-modified polyester having a Tg of 110 ° C., and the mass ratio of non-foamed polyurethane / nonwoven fabric was 15/85.

  And a fiber base material was bonded together to the resin layer of the silver surface tone formed in the uneven surface of a releasable resin sheet, it heated at 80 degreeC for 2 minutes, and was then aged at 40 degreeC for 3 days. Thus, an artificial leather with a releasable resin sheet having an uneven surface was obtained.

  Using the obtained artificial leather with a releasable resin sheet, a preform molded body was molded using a mold having a cavity in the shape of a housing of a smartphone cover. Preform molding was performed by placing artificial leather with a release resin sheet on the lower mold of a pair of molds heated to a temperature of 150 ° C., and pressing with a pressure of 0.4 MPa. A preform molded body was thus obtained.

  Then, the shape of the obtained preform molded body is in accordance with the shape of the preform molded body of the in-mold mold of the injection in-mold molding machine so that the releasable resin sheet contacts the mold surface. The ABS resin was injection molded under the conditions of a resin temperature of 235 ° C. and a mold temperature of 30 to 50 ° C. In this way, an in-mold molded body having the shape of the remote control casing was obtained. And the decorative molded body which has an artificial leather-like uneven surface was obtained by peeling the release resin sheet of the surface layer of an in-mold molded body by hand. When the depth of the obtained uneven surface was measured, the depth was about 20 μm. Moreover, the tactile sensation of the surface of the obtained decorative molded body had a texture of artificial leather, and a cushion feeling was felt on the uneven surface.

[Comparative example]
An artificial leather having a concavo-convex surface was obtained by manually peeling the release resin sheet from the same artificial leather with a release resin sheet as that produced in the examples.

  Then, instead of using the artificial leather with a releasable resin sheet in the examples, a preform molded body was obtained in the same manner as in the examples except that the artificial leather obtained by peeling the releasable resin sheet was used. The decorative molded body having an artificial leather-like uneven surface was obtained by molding and further in-mold molding. When the depth of the obtained uneven surface was measured, the depth was about 2 μm. Moreover, although the tactile sensation of the surface of the obtained decorative molded body had the texture of artificial leather, the cushion feeling and the uneven feeling were not clearly felt on the uneven surface.

  INDUSTRIAL APPLICABILITY The present invention can decorate the surfaces of injection molded articles such as vehicle interior materials, portable terminal bodies (smartphones, tablet PCs) and accessories such as cases and covers, casings of electronic devices, and cosmetic cases.

DESCRIPTION OF SYMBOLS 1 Fiber base material 2 Resin layer 2a Uncured resin 3 Artificial leather 4 Release resin sheet 4a Irregular surface 4b Resin sheet 7 Preform molding die 7a Upper die 7b Lower die 10 Artificial leather with a release resin sheet 15 Injection molding machine 16 Nozzle 17 (Injection molding) Mold 17a Movable side mold 17b Fixed side mold 17c Stripper plate 17f Sprue bush 18 Cylinder 19 Screw 20 (Trimmed) preform molded body 21 Preform molded body intermediate Molded body 31 Injection molded body 31a Molten resin 32 Runner 30 In-mold molded body 40 Decorated molded body

Claims (3)

A surface resin layer is formed on the concavo-convex surface of the releasable resin sheet having a concavo-convex surface, and an artificial leather with a releasable resin sheet is formed by further laminating a fiber substrate containing a nonwoven fabric of ultrafine fibers on the surface resin layer And a process of
Forming a preform molded body of artificial leather with a releasable resin sheet;
Arranging the preform molded body in a cavity of a mold, and injecting a molten resin to the fiber substrate side of the preform molded body to mold an in-mold molded body;
And a step of obtaining a decorative molded body by peeling the release resin sheet from the in-mold molded body.   The method for producing a decorative molded body according to claim 1, wherein the releasable resin sheet has a laminated structure in which a polyolefin resin sheet is laminated on a polyester resin sheet.   A three-dimensional shape is formed on an artificial leather with a release resin sheet obtained by laminating a fibrous base material including a surface resin layer and a nonwoven fabric of ultrafine fibers on the uneven surface of a release resin sheet having an uneven surface. A preform molded body for decorative molding, which is obtained by

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