JP2020093508A - Decorative sheet and method for manufacturing molding - Google Patents
Decorative sheet and method for manufacturing molding Download PDFInfo
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- JP2020093508A JP2020093508A JP2018234911A JP2018234911A JP2020093508A JP 2020093508 A JP2020093508 A JP 2020093508A JP 2018234911 A JP2018234911 A JP 2018234911A JP 2018234911 A JP2018234911 A JP 2018234911A JP 2020093508 A JP2020093508 A JP 2020093508A
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- thermoplastic resin
- pattern
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- 238000004519 manufacturing process Methods 0.000 title claims description 14
- 238000000465 moulding Methods 0.000 title abstract description 11
- 238000000034 method Methods 0.000 title description 17
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 56
- 239000000463 material Substances 0.000 claims abstract description 27
- 238000002844 melting Methods 0.000 claims abstract description 15
- 230000008018 melting Effects 0.000 claims abstract description 15
- 239000013078 crystal Substances 0.000 claims abstract description 12
- 239000010410 layer Substances 0.000 claims description 103
- 229920005989 resin Polymers 0.000 claims description 31
- 239000011347 resin Substances 0.000 claims description 31
- 238000002347 injection Methods 0.000 claims description 20
- 239000007924 injection Substances 0.000 claims description 20
- -1 polypropylene Polymers 0.000 claims description 9
- 239000011241 protective layer Substances 0.000 claims description 9
- 239000004743 Polypropylene Substances 0.000 claims description 5
- 239000012530 fluid Substances 0.000 claims description 5
- 229920001155 polypropylene Polymers 0.000 claims description 5
- 238000011049 filling Methods 0.000 claims description 3
- 239000000047 product Substances 0.000 description 23
- 239000007787 solid Substances 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 8
- 238000010030 laminating Methods 0.000 description 8
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 6
- 238000004049 embossing Methods 0.000 description 6
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 5
- 238000001816 cooling Methods 0.000 description 4
- 229920006038 crystalline resin Polymers 0.000 description 4
- 230000005865 ionizing radiation Effects 0.000 description 4
- 238000007639 printing Methods 0.000 description 4
- 229920001577 copolymer Polymers 0.000 description 3
- 238000001746 injection moulding Methods 0.000 description 3
- 229920005629 polypropylene homopolymer Polymers 0.000 description 3
- 229920003048 styrene butadiene rubber Polymers 0.000 description 3
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- 229920000459 Nitrile rubber Polymers 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000007646 gravure printing Methods 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 239000012948 isocyanate Substances 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 229920005862 polyol Polymers 0.000 description 2
- 239000005060 rubber Substances 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 230000001360 synchronised effect Effects 0.000 description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000002174 Styrene-butadiene Substances 0.000 description 1
- 125000003647 acryloyl group Chemical group O=C([*])C([H])=C([H])[H] 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 150000002513 isocyanates Chemical class 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 239000010985 leather Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 238000007645 offset printing Methods 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920002959 polymer blend Polymers 0.000 description 1
- SCUZVMOVTVSBLE-UHFFFAOYSA-N prop-2-enenitrile;styrene Chemical compound C=CC#N.C=CC1=CC=CC=C1 SCUZVMOVTVSBLE-UHFFFAOYSA-N 0.000 description 1
- 229920000638 styrene acrylonitrile Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 229920006352 transparent thermoplastic Polymers 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Images
Abstract
Description
本発明は、加飾シート及び成形品の製造方法に関する。 The present invention relates to a decorative sheet and a method for manufacturing a molded product.
従来、例えば、基材層と、その基材層の表面側に設けられた熱可塑性樹脂層とを有する加飾シートが提案されている（例えば、特許文献１参照。）。特許文献１に記載の加飾シートを用いた場合、加飾シートを金型で予備成型し、予備成形された加飾シートを射出用金型に挿入し、流動状態の樹脂を射出金型内に充填して樹脂を固化し、固化した樹脂と予備成型した加飾シートとを一体化することで、成型品を作製するようになっている。 Conventionally, for example, a decorative sheet having a base material layer and a thermoplastic resin layer provided on the front surface side of the base material layer has been proposed (see, for example, Patent Document 1). When the decorative sheet described in Patent Document 1 is used, the decorative sheet is preformed with a mold, the preformed decorative sheet is inserted into an injection mold, and a resin in a fluid state is injected into the injection mold. To mold the resin and to solidify the resin, and to integrate the solidified resin and the preformed decorative sheet into a molded product.
しかしながら、特許文献１に記載の加飾シートでは、成形品表面に凹凸模様を形成する場合、形成する凹凸模様を含む射出金型側を用いる必要がある。それゆえ、凹凸模様以外の成形形状が同じであっても、凹凸模様が異なる場合には、複数の金型が必要となる。
本発明は、上記のような問題点に着目してなされたもので、凹凸形状を有する成型品を容易に形成可能な加飾シート及び成形品の製造方法を提供することを目的とする。
However, in the decorative sheet described in Patent Document 1, when an uneven pattern is formed on the surface of a molded product, it is necessary to use the injection mold side including the uneven pattern to be formed. Therefore, even if the molding shapes other than the concavo-convex pattern are the same, if the concavo-convex pattern is different, a plurality of molds are required.
The present invention has been made in view of the above problems, and an object of the present invention is to provide a decorative sheet and a method of manufacturing a molded product that can easily form a molded product having an uneven shape.
上記課題を解決するために、本発明の一態様は、（ａ）基材層と、（ｂ）基材層の一方の面側に設けられた絵柄模様層と、（ｃ）絵柄模様層の基材層と反対側の面側に設けられた熱可塑性樹脂層と、を備え、（ｄ）熱可塑性樹脂層の絵柄模様層側と反対側の面には、凹凸模様が設けられている加飾シートであって、（ｅ）基材層は、非結晶性熱可塑性樹脂を含み、（ｆ）熱可塑性樹脂層は、結晶融解温度が１５０℃以上の結晶性熱可塑性樹脂を含む加飾シートであることを要旨とする。
また、本発明の他の態様は、（ａ）加飾シートを予備金型で予備成型し、予備成形された加飾シートを射出金型に挿入し、流動状態の樹脂を射出金型内に充填して樹脂を固化させて、樹脂と加飾シートとを一体化させる成型品の製造方法であって、（ｂ）射出金型の温度が５０℃以上１００℃未満である成形品の製造方法であることを要旨とする。
In order to solve the above-mentioned problems, one embodiment of the present invention comprises (a) a base material layer, (b) a picture pattern layer provided on one surface side of the base layer, and (c) a picture pattern layer. A thermoplastic resin layer provided on the surface opposite to the base material layer, and (d) an uneven pattern is provided on the surface opposite to the picture pattern layer side of the thermoplastic resin layer. A decorative sheet, wherein (e) the base material layer contains an amorphous thermoplastic resin, and (f) the thermoplastic resin layer contains a crystalline thermoplastic resin having a crystal melting temperature of 150° C. or higher. The main point is.
Another aspect of the present invention is: (a) pre-molding a decorative sheet with a preliminary mold, inserting the pre-molded decorative sheet into an injection mold, and placing the resin in a fluid state in the injection mold. A method for producing a molded product, comprising filling and solidifying a resin to integrate the resin and the decorative sheet, (b) a method for producing a molded product in which a temperature of an injection mold is 50° C. or higher and less than 100° C. The main point is.
本発明によれば、射出金型表面で加飾シートの温度を融点以下に保持することができ、加飾シート表面の凹凸形状を維持したまま成型加工を行うことができる。それゆえ、凹凸形状を有する成型品を容易に形成可能な加飾シート及び成形品の製造方法を提供できる。 According to the present invention, the temperature of the decorative sheet can be kept below the melting point on the surface of the injection mold, and the molding process can be performed while maintaining the uneven shape of the decorative sheet surface. Therefore, it is possible to provide a decorative sheet and a method of manufacturing a molded product that can easily form a molded product having an uneven shape.
以下、本発明の実施形態に係る加飾シートについて、図面を参照しつつ説明する。本発明は、以下の実施形態に限定されるものではなく、当業者の知識を基に設計の変更等の変形を加えることも可能であり、そのような変形が加えられた形態も、本発明の範囲に含まれる。また、各図面は、理解を容易にするため適宜誇張して表現している。 Hereinafter, a decorative sheet according to an embodiment of the present invention will be described with reference to the drawings. The present invention is not limited to the following embodiments, and modifications such as design changes can be added on the basis of the knowledge of those skilled in the art. It is included in the range of. In addition, each drawing is exaggerated as appropriate to facilitate understanding.
（構成）
図１に示すように、本発明の実施形態に係る加飾シート１０は、基材層１と、基材層１の一方の面１ａ側に設けられた絵柄模様層２と、絵柄模様層２の基材層１と反対側の面２ａ側に設けられた熱可塑性樹脂層３とを備えている。また、加飾シート１０の最表面、つまり、熱可塑性樹脂層３の絵柄模様層２側と反対側の面３ａ（以下、「表面３ａ」とも呼ぶ）には、エンボス加工により形成された凹凸模様４が形成されている。凹凸模様４としては、例えば、絵柄模様層２の絵柄と同調した模様、絵柄と非同調の模様を採用できる。
また、本発明の実施形態に係る加飾シート１０の総厚は、特に制限されるものではないが、４００μｍ以上５５０μｍ以下が好ましい。さらに、基材層１、絵柄模様層２及び熱可塑性樹脂層３等の積層方法としては、例えば、熱ラミネート法、ドライラミネート法、ホットメルトラミネート法、押出ラミネート法の何れかを用いることができる。
(Constitution)
As shown in FIG. 1, a decorative sheet 10 according to an embodiment of the present invention includes a base layer 1, a pattern layer 2 provided on one surface 1a side of the base layer 1, and a pattern layer 2. The base material layer 1 and the thermoplastic resin layer 3 provided on the
The total thickness of the decorative sheet 10 according to the embodiment of the present invention is not particularly limited, but is preferably 400 μm or more and 550 μm or less. Further, as a method for laminating the base material layer 1, the pattern layer 2, the thermoplastic resin layer 3, etc., for example, any one of a thermal laminating method, a dry laminating method, a hot melt laminating method and an extrusion laminating method can be used. ..
（基材層）
基材層１の材料としては、例えば、非結晶性熱可塑性樹脂を用いることができる。非結晶性熱可塑性樹脂としては、例えば、ＡＢＳ樹脂を採用できる。ＡＢＳ樹脂としては、例えば、スチレン−アクロロニトリル共重合体とＮＢＲ（ニトリルゴム）とのポリマーブレンド型、ＢＲ（ポリブタジエンゴム）或いはＳＢＲ（スチレン・ブタジエンゴム）ラテックスの共存下にスチレンとアクリルニトリルをグラフと共重合させて得られるグラフト型を採用できる。ブタジエンの含有比率は、２０重量％以上５０重量％以下が好ましい。
(Base material layer)
As the material of the base material layer 1, for example, an amorphous thermoplastic resin can be used. As the non-crystalline thermoplastic resin, for example, ABS resin can be adopted. Examples of the ABS resin include styrene-acrylonitrile in the presence of a polymer blend type of styrene-achloronitrile copolymer and NBR (nitrile rubber), BR (polybutadiene rubber) or SBR (styrene-butadiene rubber) latex. A graft type obtained by copolymerizing with a graph can be adopted. The content ratio of butadiene is preferably 20% by weight or more and 50% by weight or less.
（絵柄模様層）
絵柄模様層２は、加飾シート１０に絵柄による意匠性を付与するための層である。絵柄模様層２は、印刷インキやコーティング剤等を用いて形成される。印刷インキ等としては、特に制限はなく、従来の加飾シートにおいて絵柄模様層に使用されている印刷インキ等と同様のものを使用できる。例えば、アクリルインキを用いることができる。アクリルインキとしては、例えば、アクリルポリオール系ビヒクルにイソシアネート硬化剤を配合してなる２液硬化型ウレタン樹脂系インキを使用することができる。また、印刷方法としては、例えば、グラビア印刷法、オフセット印刷法を用いることができる。また、絵柄としては、任意の絵柄を用いることができ、例えば、木目柄、石目柄、布目柄、コルク柄、抽象柄、幾何学模様等、或いはこれらの２種類以上の組み合わせ等を用いることできる。
(Pattern layer)
The pattern layer 2 is a layer for giving the decorative sheet 10 a design property based on a pattern. The picture pattern layer 2 is formed using printing ink, a coating agent, or the like. The printing ink and the like are not particularly limited, and the same printing ink and the like used for the pattern layer in the conventional decorative sheet can be used. For example, acrylic ink can be used. As the acrylic ink, it is possible to use, for example, a two-component curable urethane resin-based ink obtained by blending an acrylic polyol-based vehicle with an isocyanate curing agent. As a printing method, for example, a gravure printing method or an offset printing method can be used. Further, as the design, any design can be used, for example, a wood grain pattern, a stone pattern, a cloth pattern, a cork pattern, an abstract pattern, a geometric pattern, or the like, or a combination of two or more kinds of these. it can.
（熱可塑性樹脂層）
熱可塑性樹脂層３の材料としては、例えば、熱可塑性樹脂を用いることができる。熱可塑性樹脂としては、例えば、結晶融解温度（結晶化温度）が１５０℃以上の結晶性熱可塑性樹脂を採用できる。結晶性熱可塑性樹脂としては、ポリプロピレン系樹脂が好ましい。特に、融点が高いため、ホモポリプロピレンが好適である。また、熱可塑性樹脂層３には、ポリプロピレン系樹脂の柔軟化に用いられる低密度ポリエチレン、エチレン−α−オレフィン共重合体、エチレン−プロピレン共重合ゴム、エチレン−プロピレン−非共役ジエン共重合ゴム、スチレン−ブタジエン共重合体、又はその水素添加物等の改質剤を適宜添加できる。また、結晶融解温度は、例えば、示差走査熱量計（ＤＳＣ）等で測定できる。
(Thermoplastic resin layer)
As the material of the thermoplastic resin layer 3, for example, a thermoplastic resin can be used. As the thermoplastic resin, for example, a crystalline thermoplastic resin having a crystal melting temperature (crystallization temperature) of 150° C. or higher can be adopted. A polypropylene resin is preferable as the crystalline thermoplastic resin. In particular, homopolypropylene is preferable because it has a high melting point. Further, the thermoplastic resin layer 3 includes low-density polyethylene used for softening polypropylene resin, ethylene-α-olefin copolymer, ethylene-propylene copolymer rubber, ethylene-propylene-non-conjugated diene copolymer rubber, A modifier such as a styrene-butadiene copolymer or a hydrogenated product thereof can be added as appropriate. The crystal melting temperature can be measured with, for example, a differential scanning calorimeter (DSC).
（凹凸模様）
凹凸模様４は、加飾シート１０の表面に立体的な意匠感を付与するために、必要に応じて設けられるものである。凹凸模様４としては、任意の凹凸形状を用いることができ、例えば、木目導管状、石目状、布目状、抽象柄状、和紙状、スウェード状、皮革状、梨地状、砂目状、ヘアーライン状、或いはこれらの組み合わせ等を用いることができる。また凹凸模様４の形成方法としては、例えば、熱可塑性樹脂層３の積層前、積層後又は積層と同時に行われる、ダブリングエンボス法、押出ラミネート同時エンボス法等を採用できる。
(Uneven pattern)
The concavo-convex pattern 4 is provided as needed in order to give a three-dimensional design feeling to the surface of the decorative sheet 10. As the concavo-convex pattern 4, any concavo-convex shape can be used, and for example, wood grain conduit shape, stone shape, cloth shape, abstract pattern shape, Japanese paper shape, suede shape, leather shape, satin shape, grain shape, hairline. Shape, or a combination thereof can be used. As a method for forming the uneven pattern 4, for example, a doubling embossing method, an extrusion laminating simultaneous embossing method, or the like, which is performed before, after, or simultaneously with the lamination of the thermoplastic resin layer 3, can be adopted.
（その他の層）
また、加飾シート１０は、従来の加飾シートと同様に、基材層１、絵柄模様層２及び熱可塑性樹脂層３以外にも、表面保護層５及びベタ層６等を適宜備えるようにしてもよい。表面保護層５は、熱可塑性樹脂層３の表面３ａ側に設けられる。ベタ層６は、基材層１と絵柄模様層２との層間に設けられる。図１では、基材層１の一方の面１ａに、ベタ層６、絵柄模様層２、熱可塑性樹脂層３及び表面保護層５がこの順に積層されている。
(Other layers)
Further, the decorative sheet 10 is appropriately provided with a surface protective layer 5, a solid layer 6 and the like in addition to the base material layer 1, the pattern layer 2 and the thermoplastic resin layer 3 as in the conventional decorative sheet. May be. The surface protective layer 5 is provided on the surface 3a side of the thermoplastic resin layer 3. The solid layer 6 is provided between the base layer 1 and the pattern layer 2. In FIG. 1, a solid layer 6, a pattern layer 2, a thermoplastic resin layer 3, and a surface protective layer 5 are laminated in this order on one surface 1a of the base material layer 1.
（表面保護層）
表面保護層５は、加飾シート１０の表面形状の保持性を向上し、且つ、成形後の成形品表面の耐傷性、耐汚染性、耐候性を向上させるために、必要に応じて設けられる層である。表面保護層５の材料としては、例えば、硬化性樹脂を用いることができる。硬化型樹脂としては、例えば、電離放射線硬化型樹脂、アクリルウレタン系樹脂を採用することができる。電離放射線硬化性樹脂とは、電離放射線の照射により架橋反応する性質を有する（メタ）アクリロイル基等の重合性不飽和結合を有するプレポリマー、オリゴマー及びモノマーの少なくとも何れかを主成分とする組成物である。電離放射線としては、例えば、電子線、紫外線を採用できる。アクリルウレタン系樹脂としては、例えば、アクリルポリオール化合物を主剤とし、イソシアネート化合物を硬化剤とした反応生成物を採用できる。
(Surface protection layer)
The surface protective layer 5 is provided as necessary in order to improve the retention of the surface shape of the decorative sheet 10 and to improve the scratch resistance, stain resistance, and weather resistance of the surface of the molded product after molding. It is a layer. As a material for the surface protective layer 5, for example, a curable resin can be used. As the curable resin, for example, an ionizing radiation curable resin or an acrylic urethane resin can be adopted. The ionizing radiation curable resin is a composition containing as a main component at least one of a prepolymer having a polymerizable unsaturated bond such as a (meth)acryloyl group having the property of undergoing a crosslinking reaction upon irradiation with ionizing radiation, an oligomer and a monomer. Is. As the ionizing radiation, for example, an electron beam or ultraviolet ray can be adopted. As the acrylic urethane-based resin, for example, a reaction product containing an acrylic polyol compound as a main component and an isocyanate compound as a curing agent can be adopted.
（ベタ層）
ベタ層６は、絵柄模様層２の絵柄の意匠性を向上させるために、必要に応じて設けられる層である。ベタ層６の材料としては、着色された熱可塑性樹脂を用いることができる。
(Solid layer)
The solid layer 6 is a layer provided as needed in order to improve the design of the design of the design pattern layer 2. As the material of the solid layer 6, a colored thermoplastic resin can be used.
（成型品の製造方法）
本発明の実施形態に係る加飾シート１０は、樹脂等からなる被着体に積層することで、被着体を加飾した成型品を作製することができる。成型品の製造方法としては、例えば、射出成型同時積層法を用いることができる。射出成型同時積層法は、加飾シート１０を予備金型で予備成型し、予備成形された加飾シート１０を射出金型に挿入し、流動状態の樹脂を射出金型内に充填して樹脂を固化させて、樹脂と加飾シートとを一体化させる方法である。その際、予備金型の温度は、１２０℃以上１３０℃未満とする。インジェクション成型での型冷却温度は、５０℃を下回ると射出樹脂の広がりが悪くなるため５０℃以上が望ましく、１００℃を超えると表面形状保持が悪くなるため、１００℃未満が望ましい。
(Molded product manufacturing method)
The decorative sheet 10 according to the embodiment of the present invention can be laminated on an adherend made of a resin or the like to produce a molded product with the adherend decorated. As a method of manufacturing a molded product, for example, an injection molding simultaneous laminating method can be used. In the injection molding simultaneous laminating method, the decorative sheet 10 is preformed by a preliminary mold, the preformed decorative sheet 10 is inserted into the injection mold, and a resin in a fluid state is filled in the injection mold to make the resin. Is solidified to integrate the resin and the decorative sheet. At that time, the temperature of the preliminary mold is 120° C. or higher and lower than 130° C. The mold cooling temperature in injection molding is preferably 50° C. or higher because the injection resin spreads poorly when the temperature is lower than 50° C., and less than 100° C. when the mold shape cooling temperature exceeds 100° C. because the surface shape retention becomes poor.
以上説明したように、本発明の実施形態に係る加飾シート１０は、基材層１と、基材層１の一方の面１ａ側に設けられた絵柄模様層２と、絵柄模様層２の基材層１と反対側の面２ａ側に設けられた熱可塑性樹脂層３とを備えている。また、熱可塑性樹脂層３の絵柄模様層２側と反対側の面３ａには、凹凸模様４が設けられている。そして、基材層１は非結晶性熱可塑性樹脂を含み、熱可塑性樹脂層３は結晶融解温度が１５０℃以上の結晶性熱可塑性樹脂を含む。それゆえ、射出金型表面で加飾シート１０の温度を融点以下に保持することができ、加飾シート１０表面の凹凸形状を維持したまま成型加工を行うことができる。それゆえ、凹凸形状を有する成型品を容易に形成可能な加飾シート１０を提供できる。
As described above, the decorative sheet 10 according to the embodiment of the present invention includes the base layer 1, the pattern layer 2 provided on the one surface 1a side of the base layer 1, and the pattern layer 2. The base material layer 1 and the thermoplastic resin layer 3 provided on the
また、凹凸模様以外の成形形状が同じである場合には、同一の射出金型を用いることができる。それゆえ、射出金型の数を低減でき、射出金型の製造コストを低減できる。
また、結晶性熱可塑性樹脂は、一般に熱成型性が悪く、急激に変形する特性を有する。それゆえ、結晶性熱可塑性樹脂を含む熱可塑性樹脂層３に、成型時支持層として、非晶性熱可塑性樹脂を含む基材層１を貼り合せることで、成型性を持たせることができる。
また、本発明の実施形態に係る加飾シート１０は、結晶性熱可塑性樹脂が、ポリプロピレン系樹脂である。それゆえ、比較的簡単に入手でき、製造コストを低減できる。
Further, when the molding shapes other than the concavo-convex pattern are the same, the same injection mold can be used. Therefore, the number of injection molds can be reduced, and the manufacturing cost of the injection molds can be reduced.
Further, the crystalline thermoplastic resin generally has poor thermoformability and has a characteristic of being rapidly deformed. Therefore, by molding the thermoplastic resin layer 3 containing the crystalline thermoplastic resin and the base material layer 1 containing the amorphous thermoplastic resin as a supporting layer at the time of molding, it is possible to provide moldability.
In the decorative sheet 10 according to the embodiment of the present invention, the crystalline thermoplastic resin is polypropylene resin. Therefore, it can be obtained relatively easily and the manufacturing cost can be reduced.
また、本発明の実施形態に係る加飾シート１０は、熱可塑性樹脂層３の絵柄模様層２側と反対側の面３ａ側に設けられた表面保護層５を更に備えている。それゆえ、加飾シート１０の表面形状の保持性を向上でき、また、成形後の成型品表面の耐傷性、耐汚染性、耐候性を向上できる。
また、本発明の実施形態に係る加飾シート１０は、加飾シート１０を予備金型で予備成型し、予備成形された加飾シート１０を射出金型に挿入し、流動状態の樹脂を射出金型内に充填して樹脂を固化させて、樹脂と加飾シート１０とを一体化させる成型品の製造方法である。そして、予備金型の温度を５０℃以上１００℃未満とした。それゆえ、凹凸形状を有する成型品を容易に形成可能な成型品の製造方法を提供することができる。
The decorative sheet 10 according to the embodiment of the present invention further includes a surface protective layer 5 provided on the surface 3a side of the thermoplastic resin layer 3 opposite to the pattern layer 2 side. Therefore, the retainability of the surface shape of the decorative sheet 10 can be improved, and the scratch resistance, stain resistance, and weather resistance of the surface of the molded product after molding can be improved.
Further, the decorative sheet 10 according to the embodiment of the present invention is obtained by preforming the decorative sheet 10 with a preliminary mold, inserting the preformed decorative sheet 10 into an injection mold, and injecting a resin in a fluidized state. It is a method of manufacturing a molded product in which the resin and the decorative sheet 10 are integrated by filling the inside of a mold to solidify the resin. Then, the temperature of the preliminary mold was set to 50° C. or higher and lower than 100° C. Therefore, it is possible to provide a method of manufacturing a molded product that can easily form a molded product having an uneven shape.
以下に、本発明の実施形態に係る加飾シート１０の実施例及び比較例について説明する。なお、本発明は、下記の実施例に限定されるものではない。 Examples and comparative examples of the decorative sheet 10 according to the embodiment of the present invention will be described below. The present invention is not limited to the examples below.
（実施例１）
まず、ベタ層６として、着色顔料を添加したランダムポリプロピレン系樹脂のフィルムを用意した。フィルムの厚さは、７０μｍとした。続いて、ベタ層６の一方の面に、グラビア印刷でアクリルインキによる絵柄模様層２を形成した。続いて、溶融させた結晶性樹脂をＴダイで成膜して熱可塑性樹脂層３を形成した。結晶融解温度としては、例えば、結晶融解温度が１８０℃のホモポリプロピレンを採用できる。結晶溶融温度は、示差走査熱量計（パーキンエルマー社製、ＤＳＣ８５００）で測定した。そして、熱可塑性樹脂層３を、凹凸のエンボス形状を持った冷却ロールで凹凸転写及び冷却固化させると同時にベタ層６の絵柄模様層２側の面に積層させた。
(Example 1)
First, as the solid layer 6, a film of a random polypropylene resin to which a color pigment was added was prepared. The thickness of the film was 70 μm. Subsequently, a pattern layer 2 made of acrylic ink was formed on one surface of the solid layer 6 by gravure printing. Then, the melted crystalline resin was formed into a film with a T die to form the thermoplastic resin layer 3. As the crystal melting temperature, for example, homopolypropylene having a crystal melting temperature of 180° C. can be adopted. The crystal melting temperature was measured by a differential scanning calorimeter (DSC8500 manufactured by Perkin Elmer Co., Ltd.). Then, the thermoplastic resin layer 3 was transferred onto the surface of the solid layer 6 on the side of the picture pattern layer 2 while being transferred and solidified by cooling with a cooling roll having an uneven embossed shape.
続いて、凹凸が転写された熱可塑性樹脂層３の表面に、アクリル樹脂系の熱硬化性樹脂をコーティングして、表面保護層５を形成した。表面保護層５のコーティングは、ドライ状態で６ｇ/ｍ2とした。これにより、化粧シート７を作製した。続いて、作製した化粧シート７のベタ層６側の面に、非結晶性熱可塑性樹脂（着色ＡＢＳ樹脂）を１００μｍの厚さで成膜した基材層１を積層した。これにより、実施例１の加飾シート１０を作製した。
続いて、製作した加飾シート１０を予備成形金型を使って１３０℃に加熱し、圧空成形で予備成形金型に沿って予備成形を行った。その際、熱可塑性樹脂層３を構成する結晶性樹脂（ホモポリプロピレン）の結晶融解温度は１５０℃以上であるため、熱エンボスロールによって転写された凹凸形状は熱圧に耐えた。続いて、予備成型されたシートを射出金型に挿入し、流動状態のＡＢＳ樹脂を者射出金型内に充填してＡＢＳ樹脂を固化させ、ＡＢＳ樹脂と加飾シート１０とを一体化させて成型品（加飾凹凸付き成形パーツ）を得た。
Then, the surface of the thermoplastic resin layer 3 on which the irregularities were transferred was coated with an acrylic resin-based thermosetting resin to form a surface protective layer 5. The coating of the surface protective layer 5 was 6 g/m 2 in a dry state. Thus, the decorative sheet 7 was produced. Subsequently, the base material layer 1 in which a non-crystalline thermoplastic resin (colored ABS resin) was formed to a thickness of 100 μm was laminated on the surface of the produced decorative sheet 7 on the solid layer 6 side. This produced the decorative sheet 10 of Example 1.
Subsequently, the produced decorative sheet 10 was heated to 130° C. using a preforming die, and preformed by pressure forming along the preforming die. At that time, since the crystal melting temperature of the crystalline resin (homopolypropylene) constituting the thermoplastic resin layer 3 was 150° C. or higher, the uneven shape transferred by the hot embossing roll withstood the heat pressure. Then, the preformed sheet is inserted into an injection mold, and the ABS resin in a fluid state is filled in the injection mold to solidify the ABS resin, and the ABS resin and the decorative sheet 10 are integrated. A molded product (molded part with decorative unevenness) was obtained.
（比較例１）
比較例１では、熱可塑性樹脂層３の形成について、結晶性樹脂の代わりに、透明熱可塑性樹脂（アクリル樹脂）を厚さ１００μｍのシート状に成膜して熱可塑性樹脂層３を形成した以外は、実施例１と同様にして、比較例１の加飾シート１０及び成型品を得た。なお、予備成形の時点で、熱エンボスロールによって転写された凹凸形状は消失していた。
(Comparative Example 1)
In Comparative Example 1, regarding the formation of the thermoplastic resin layer 3, a transparent thermoplastic resin (acrylic resin) was formed into a sheet having a thickness of 100 μm in place of the crystalline resin to form the thermoplastic resin layer 3. In the same manner as in Example 1, a decorative sheet 10 of Comparative Example 1 and a molded product were obtained. At the time of preforming, the uneven shape transferred by the hot embossing roll disappeared.
（比較例２）
比較例２では、熱可塑性樹脂層３の形成について、結晶性樹脂の代わりに、結晶融解温度が１４０℃のＨＤＰＥ樹脂を用いて熱可塑性樹脂層３を形成した以外は、実施例１と同様にして、比較例１の加飾シート１０及び成型品を得た。なお、予備成形の時点で、予備成形金型によって１００℃に加熱されるため、熱エンボスロールによって転写された凹凸形状（結晶融解温度１４０℃のＨＤＰＥ樹脂）は歪んで崩れていた。
(Comparative example 2)
In Comparative Example 2, the thermoplastic resin layer 3 was formed in the same manner as in Example 1 except that the HDPE resin having a crystal melting temperature of 140° C. was used instead of the crystalline resin to form the thermoplastic resin layer 3. Thus, a decorative sheet 10 of Comparative Example 1 and a molded product were obtained. At the time of preforming, since it was heated to 100° C. by the preforming die, the uneven shape (HDPE resin having a crystal melting temperature of 140° C.) transferred by the hot embossing roll was distorted and collapsed.
したがって、実施例１の加飾シート１０は、比較例１、２の加飾シート１０に比べ、凹凸形状を有する成型品を容易に形成できることが確認できた。 Therefore, it was confirmed that the decorative sheet 10 of Example 1 could easily form a molded product having an uneven shape as compared with the decorative sheets 10 of Comparative Examples 1 and 2.
１…基材層、２…絵柄模様層、３…熱可塑性樹脂層、４…凹凸模様、５…表面保護層、６…ベタ層、７…化粧シート、１０…加飾シート DESCRIPTION OF SYMBOLS 1... Base material layer, 2... Design pattern layer, 3... Thermoplastic resin layer, 4... Uneven pattern, 5... Surface protection layer, 6... Solid layer, 7... Decorative sheet, 10... Decorative sheet
Claims (4)
前記基材層の一方の面側に設けられた絵柄模様層と、
前記絵柄模様層の前記基材層と反対側の面側に設けられた熱可塑性樹脂層と、を備え、
前記熱可塑性樹脂層の前記絵柄模様層側と反対側の面には、凹凸模様が設けられている加飾シートであって、
前記基材層は、非結晶性熱可塑性樹脂を含み、
前記熱可塑性樹脂層は、結晶融解温度が１５０℃以上の結晶性熱可塑性樹脂を含むことを特徴とする加飾シート。 A base material layer,
A pattern layer provided on one surface side of the base layer,
A thermoplastic resin layer provided on the surface side of the picture pattern layer opposite to the base material layer,
A decorative sheet provided with an uneven pattern on the surface of the thermoplastic resin layer opposite to the pattern layer side,
The base material layer contains an amorphous thermoplastic resin,
The decorative sheet, wherein the thermoplastic resin layer contains a crystalline thermoplastic resin having a crystal melting temperature of 150° C. or higher.
前記射出金型の温度が５０℃以上１００℃未満であることを特徴とする成形品の製造方法。 The decorative sheet according to any one of claims 1 to 3 is preformed in a preliminary mold, the preformed decorative sheet is inserted into an injection mold, and a resin in a fluid state is injected into the injection mold. A method for producing a molded article, wherein the resin and the decorative sheet are integrated by filling the
A method for producing a molded article, wherein the temperature of the injection mold is 50° C. or higher and lower than 100° C.
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