JP2979019B2 - Molding film and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding film used as a raw material of a molded article used as a package or a case by molding, or a molded article used as a part of a toy, an electric product, an automobile or the like. The present invention relates to the manufacturing method.

[0002]

2. Description of the Related Art A moldable film is formed into a molded product by vacuum molding or press molding, and is formed into a case, a package, or
Some are used as various parts. Then, in order to impart a decorative effect to these molded articles, there is a method of molding after providing a design layer (see FIG. 8) (see FIGS. 9 to 11).

In the above method, a pattern is printed on one surface of a moldable film using an ultraviolet-curable ink, and the ultraviolet-curable ink is cured by irradiation with ultraviolet rays to form a symbol layer. The reason that a normal printing ink is not used to form the pattern layer is that the moldable film is heated in the ink drying step, and the dimensional stability of the moldable film cannot be maintained. Therefore,
To form the pattern layer, an ultraviolet curable ink that does not require heating to solidify the ink is used.

[0004]

However, according to the prior art, a single moldable film is formed.
If the film thickness of the moldable film is small, it is difficult to handle, and it is necessary to use a film that is thicker than necessary, which is uneconomical.

[0005] Further, since the ultraviolet curable ink film constituting the design layer is inferior in moldability, there is a problem that cracks are generated when the moldable film is formed, resulting in poor appearance.

In addition, dimensional stability of a moldable film cannot be maintained due to preheating during molding, and it is difficult to align a design with a molded product (see FIG. 11). In particular, when the molded product has a large area, it is difficult to obtain a product having the same register.

Accordingly, the present invention solves the above-mentioned problems and enables molding even with a thin film, and has a good pattern layer with excellent moldability and good appearance without cracks. It is an object of the present invention to provide a molding film capable of producing a molded film with easy product alignment with high productivity and a method for producing the same.

[0008]

Means for Solving the Problems A molding film and a method of manufacturing the same according to the present invention have the following constitutions in order to achieve the above objects.

That is, the molding film of the present invention is formed by laminating a support film having good dimensional stability on one surface of a transparent and moldable film so that the support film can be completely peeled off. A half-cut or broken line-shaped perforation is provided at the boundary between the portion overlapping the molded portion of the moldable film and the portion overlapping the non-molded portion of the moldable film, and the pattern layer can be formed on the other surface of the moldable film. Was provided.

In the above invention, the formable film may be configured to be long.

Further, in the above invention, the formable film and the support film may be configured so as to be thermocompression-bonded.

Further, in the above invention, the formable film and the support film may be configured to be laminated via an adhesive or a pressure-sensitive adhesive.

Further, according to the method for producing a molding film of the present invention, a support film having good dimensional stability is entirely laminated on one surface of a transparent moldable film, and a design layer is formed on the other surface. Was formed, a half-cut or break-line perforation was provided at the boundary between the portion of the support film overlapping the molded portion of the moldable film and the portion overlapping the non-molded portion of the moldable film.

Further, according to the method for producing a molding film of the present invention, a support film having good dimensional stability is entirely laminated on one side of a transparent and moldable moldable film, and the moldable film is formed on the support film. After forming a half-cut or broken line-shaped perforation at the boundary between the portion overlapping the molded portion and the portion overlapping the non-molded portion of the moldable film, a pattern layer is formed on the other surface of the moldable film. Configured.

[0015] In the above invention, the formable film and the supporting film may be laminated by thermocompression bonding.

Further, in the above invention, the formable film and the support film may be laminated via an adhesive or a pressure-sensitive adhesive.

Further, the method for producing a molding film of the present invention comprises the steps of: casting a molten or dissolved resin on a support film having good dimensional stability; drying and cooling to form a transparent moldable film; Next, a pattern layer is formed on the moldable film, and then a half-cut or broken line-shaped perforation is formed at the boundary between the portion of the support film that overlaps the molded portion of the moldable film and the portion that overlaps the non-molded portion of the moldable film. Was provided.

[0018]

Embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view showing an embodiment of the molding film of the present invention. FIG. 2 is a sectional view showing one step of the method for producing a molding film of the present invention. FIG. 3-
FIG. 4 is a sectional view showing a step of obtaining a molded product from the molding film of the present invention. FIG. 5 is a sectional view showing one embodiment of a molded product obtained by using the molding film of the present invention.
FIG. 6 is a plan view showing one embodiment of the molding film of the present invention. FIG. 7 is a plan view showing another embodiment of the molding film of the present invention. In the figure, 1 is a molding film, 2 is a moldable film, 3 is a support film, 4 is a design layer, 5 is a mold, 6 is a molded product, and 7 is a half cut or broken linear perforation.

The film for molding 1 of the present invention is formed by laminating a support film 3 having good dimensional stability on one surface of a transparent and moldable formable film 2 so as to be completely peelable. In the above, a half-cut or broken-line perforation 7 is provided at a boundary between a portion overlapping the molding portion of the moldable film 2 and a portion overlapping the non-molding portion of the moldability film 2, and the other surface of the moldability film 2 is provided. Is provided with a design layer 4 that can be molded (see FIG. 1).

The moldable film 2 is a transparent film made of an acrylic resin, a nylon resin, a urethane resin, an olefin resin, or a mixture of a thermoplastic elastomer and a non-stretched film. Alternatively, a low-stretch polyester film or the like may be used. The thickness is preferably from 20 to 300 μm.

As the support film 3, a plastic film having excellent dimensional stability and heat resistance, such as a biaxially stretched polyester film, a polyether olefin film, and a polyimide film, paper, and metal foil can be used. The thickness is preferably from 20 to 300 μm.

The moldable film 2 and the support film 3 are
Lamination may be performed by thermocompression bonding or an adhesive or a pressure-sensitive adhesive.

In the case of thermocompression bonding, it is preferable that the temperature of the heated formable film 2 and the support film 3 is not higher than the softening temperature of the formable film 2 by 30 ° C. or more. If the temperature is higher than the softening temperature of the moldable film 2 by 30 ° C. or more, wrinkles and the like may occur due to expansion and contraction of the moldable film 2.

As the adhesive or the pressure-sensitive adhesive, an acrylic resin or a vinyl resin is suitable. It is desirable that the adhesive or the pressure-sensitive adhesive adheres to the support film 3 and does not remain on the moldable film 2 after peeling.

When an adhesive is used, a solution dissolved or dispersed in a solvent or the like is applied using a gravure coater, a reverse coater, a lip coater or the like to a thickness of about 0.1 to 30 μm, and is pressed by a laminator. Since it is necessary to remove the unnecessary support film 3 later, the peeling load is 10 to 40.
Desirably, it is 0 g / cm.

The design layer 4 is formed on the surface of the moldable film 2 on which the support film 3 is not laminated. The design layer 4 needs to have moldable flexibility. As a material of the pattern layer 4, a urethane-based resin, a vinyl-based resin, a polyester-based resin, an acrylic-based resin, and the like, in particular, a urethane-based resin, and an elastomer thereof are used as a binder.
It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. In particular, an offset printing method or a gravure printing method is suitable for performing multicolor printing and gradation expression. In the case of a single color, a coating method such as a gravure coating method, a roll coating method, and a comma coating method can be adopted.

Further, a metal thin film layer may be used as the design layer 4. The metal thin film layer is for expressing metallic luster, and is formed by a vacuum evaporation method, a sputtering method, an ion plating method, a plating method, or the like. Aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium,
Use metals such as lead and zinc, their alloys or compounds. As an example of forming a partial metal thin film layer, after forming a solvent-soluble resin layer in a portion that does not require a metal thin film layer, a metal thin film is entirely formed thereon, and solvent cleaning is performed. There is a method of removing an unnecessary metal thin film together with the solvent-soluble resin layer. The solvent often used in this case is
It is water or an aqueous solution. As another example, there is a method in which a metal thin film is formed on the entire surface, a resist layer is formed on a portion where the metal thin film is to be left, and the resist layer is removed by etching with an acid or an alkali. . In addition,
In providing the metal thin film layer, a front anchor layer or a rear anchor layer may be provided in order to improve the adhesion of the metal thin film layer. As the material of the front anchor layer and the rear anchor layer,
Uses two-part curable urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, acrylic resin, epoxy resin, vinyl copolymer resin, etc. Good to do. Examples of a method for forming the front anchor layer and the rear anchor layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method. In particular, when a metal thin film layer is provided in a portion stretched by molding, it is preferable to provide a cluster vapor-deposited film of indium or tin.

Formable film 2 in support film 3
A half-cut or broken-line perforation 7 is provided at a boundary between a portion overlapping the molded portion and a portion overlapping the non-molded portion of the moldable film 2 (see FIG. 1). The half cut means a cut that does not completely cut the support film 3. Further, the perforations in the form of broken lines refer to perforations having a shape like a perforation or the like, in which a number of cuts penetrating the support film 3 and non-penetrating portions are continuous.
The provision of the half-cut or broken linear perforations 7
It may be before or after the formation of the pattern layer 4.

In order to form a half cut, a Thomson method, a laser method, a dice cut method, or the like may be used.
That is, in the case of the Thomson method, a Thomson blade is fixed to a press machine, a film is set at a predetermined position, and then a cut is made from the support film 3 side by pressing. In the case of the laser method or the dice-cut method, a continuous cut is made by scanning the part to be cut with a laser or a dice.

Further, in order to form a break-shaped perforation, a Thomson method, a laser method, or the like may be used. That is,
What is necessary is just to press using the Thomson blade which has a saw blade-shaped edge. Further, in the laser method, a laser scans a portion to be cut and irradiates the laser intermittently.

Half cut or broken line perforations 7
Is preferably provided in a shape surrounding the part to be molded (see FIG. 6). Further, the shape may surround a part of the portion to be formed (see FIG. 7).

In this manner, the molding film 1 can be obtained.

The method of manufacturing the molding film 1 is merely an example, and other manufacturing methods may be used. For example, the formable film 2 is formed on the support film 3 by casting, and then the formable film 2 is formed.
A pattern layer 4 is formed thereon, and then a half-cut or broken-line perforation is formed at a boundary between a portion of the support film 3 that overlaps the molded portion of the moldable film 2 and a portion that overlaps the non-molded portion of the moldable film 2. 7 may be provided. The material to be cast is coated on the support film 3 with a constant thickness by heating to a melting point or more and melting.
After cooling, it can be formed into a film-like film. Also,
A film-like film may be formed by coating a solution in a solvent and evaporating and drying the solvent.

In order to obtain a molded product 6 using the molding film 1, it is preferable to carry out the following.

First, the molding film 1 is placed in the mold 5 (see FIG. 3). At that time, the sheet forming film may be fed one by one, or a necessary portion of the long forming film may be sent intermittently. When the long molding film 1 is used, it is preferable to use a feeding device having a positioning mechanism so that the register of the design layer 4 of the molding film 1 and the mold 5 coincide. When the film 1 is intermittently fed, if the position of the film 1 is detected by a sensor and then the film 1 is fixed, the film 1 is always fixed at the same position. This is convenient because no misalignment of the symbol layer 4 occurs.

Next, the molding film 1 is heated and softened by a heat source, and is adhered to the surface of the mold 5 by vacuum suction and / or air pressure (see FIG. 4). At this time, the moldable film 2 is stretched following the mold,
Since the support film 3 does not follow the mold, the support film 3 is cut at the half-cut or broken-line perforations 7 and peeled off from the molded portion of the formable film 2.

Next, the molding film 1 is taken out of the mold 5. Finally, the support film 3 is removed (see FIG. 5). Thus, the molded product 6 can be obtained.

[0039]

Example: Release paper having a thickness of 100 μm was used as a support film.
A molten urethane resin was formed thereon by extrusion molding so as to have a thickness of 100 μm, and a moldable film was laminated.

Next, a pattern layer was formed on the surface of the moldable film by a screen printing method, and only the support film was half-cut with a laser in a shape surrounding the portion to be molded to obtain a molding film.

When molding was performed using this molding film, it could be molded into a package by vacuum molding. Also, even when a plurality of packages are molded at the same time, the workability is good because the thin film is held by the support film, and the pattern layer has excellent moldability and good appearance without cracking. The alignment between the design and the molded product was finished with high accuracy.

[0042]

Since the present invention has the above-described structure, it has the following effects.

The molding film of the present invention can be molded even if the molding film is a thin film because the supporting film is laminated on the molding film. In addition, since the pattern layer has excellent moldability, the appearance is good without cracks. In addition, since the dimensional stability of the film for molding is excellent, it is easy to align the pattern with the molded product.

Further, according to the method for producing a molding film of the present invention, the above-mentioned molding film can be easily obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of a molding film of the present invention.

FIG. 2 is a cross-sectional view showing one step of the method for producing a molding film of the present invention.

FIG. 3 is a cross-sectional view showing a step of obtaining a molded product from the molding film of the present invention.

FIG. 4 is a cross-sectional view showing a step of obtaining a molded product from the molding film of the present invention.

FIG. 5 is a cross-sectional view showing one embodiment of a molded product obtained by using the molding film of the present invention.

FIG. 6 is a plan view showing an embodiment of the molding film of the present invention.

FIG. 7 is a plan view showing another embodiment of the molding film of the present invention.

FIG. 8 is a cross-sectional view showing one example of a conventional molding film.

FIG. 9 is a cross-sectional view illustrating a step of obtaining a molded product from a conventional molding film.

FIG. 10 is a cross-sectional view showing a step of obtaining a molded product from a conventional molding film.

FIG. 11 is a cross-sectional view showing one embodiment of a molded product obtained from a conventional molding film.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Forming film 2 Formable film 3 Support film 4 Pattern layer 5 Die 6 Molded product 7 Half cut or broken linear perforation

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Claims (9)

(57) [Claims] 1. A support film having good dimensional stability is laminated on one surface of a transparent and moldable moldable film so as to be entirely peelable, and overlaps with a molding portion of the moldable film in the support film. A half-cut or break-shaped perforation is provided at the boundary between the portion and the portion overlapping the non-moldable portion of the moldable film, and a moldable design layer is provided on the other surface of the moldable film. Film for molding. 2. The molding film according to claim 1, wherein the molding film is long. 3. The molding film according to claim 1, wherein the molding film and the supporting film are thermocompression-bonded. 4. The method according to claim 1, wherein the moldable film and the support film are laminated via an adhesive or a pressure-sensitive adhesive.
3. The molding film according to any one of 2. 5. A transparent and formable moldable film, a support film having good dimensional stability is entirely laminated on one surface and a pattern layer is formed on the other surface, and then the moldable film is formed on the support film. Forming a half-cut or broken-line perforation at a boundary between a portion overlapping the molded portion and a portion overlapping the non-molded portion of the moldable film. 6. A transparent and moldable formable film, on which a support film having good dimensional stability is entirely laminated on one surface, and a portion of the support film which overlaps a molded portion of the formable film and a formable film. Forming a pattern layer on the other surface of the moldable film after forming a half-cut or broken-line perforation at the boundary between the non-molded portion and the portion overlapping with the non-molded portion. 7. The method for producing a molding film according to claim 5, wherein the moldable film and the support film are laminated by thermocompression bonding. 8. The method according to claim 5, wherein the moldable film and the support film are laminated via an adhesive or a pressure-sensitive adhesive. 9. A resin in a molten or dissolved state is cast on a support film having good dimensional stability, and is dried and dried.
Cooling to form a transparent moldable film, then forming a pattern layer on the moldable film, and then in the support film, the part overlapping the molded part of the moldable film and the part overlapping the non-molded part of the moldable film And forming a half-cut or broken-line perforation at the boundary of the film.