JP3117032B2 - Molded body with uneven surface - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded article such as a transfer article or a press molded article having fine irregularities on the surface, which is formed by using a molding film.

[0002]

2. Description of the Related Art Heretofore, as a technique for forming fine irregularities on a surface of a molded article, that is, a matte surface called a mat, there has been a technique described below. First, a technique for forming fine irregularities on the surface of a transfer-receiving body using a transfer sheet will be described. The transfer sheet is formed by forming a transfer layer composed of a release layer, a picture layer, and an adhesive layer on a peelable base material sheet. This is a technique in which the adhesive layer, the pattern layer, and the release layer are transferred to the surface of the transfer body in this order and transferred. Therefore, the surface of the transfer object becomes a release layer. Conventionally, in order to form an uneven pattern on the surface of such a transferred object, a transfer sheet is formed on the surface of a peelable substrate sheet in which the uneven pattern is formed in advance, and the transferred layer is formed thereon. The transfer was performed by contacting the transfer member. Due to this transfer, the transfer layer having a concavo-convex pattern was transferred to the surface of the transfer object, and a mat-like surface was obtained.

Next, a conventional technique for forming fine irregularities on the surface of a molded article will be described. Molded products include, for example, decorative plates, which are made by impregnating decorative base paper with a thermosetting resin, drying the laminated product together with core paper, overlay paper, and a base film, and placing this between the upper and lower hot plates. Is heated and pressed with a metal mirror plate interposed therebetween. On such a decorative board, for example, a melamine resin-impregnated paper is laminated on about four sheets of phenol resin-impregnated core paper, and an overlay paper impregnated with melamine resin is further laminated thereon and heated and pressed. There is a melamine decorative board. Further, as another example, a diallyl phthalate (hereinafter abbreviated as DAP) resin-impregnated paper is sequentially stacked on a plate-shaped base material, and heated and pressed.
There is a P decorative panel. When imparting irregularities on the surface of these decorative plates, insert a shaping film having irregularities on the surface between the mirror-finished plates, sandwich the plate-shaped substrate, heat-press and mold, and then, The decorative plate obtained by releasing the mold had irregularities on the surface.

Further, as another example of a molded article, an ionizing radiation-curable resin is applied to the surface of an object to be coated, and a molding film having irregularities formed on the surface is covered thereon, and is irradiated with ionizing radiation. Thus, the coating film was cured, and the imprinted film having the irregularities formed on the surface was peeled off to obtain an object having irregularities on the surface. Furthermore, as another example of a molded article, a molded film having an uneven surface is formed by covering a molded film with a material impregnated with an unsaturated polyester resin, curing the resin, and peeling the molded film. Was getting.

[0005]

However, molded articles manufactured using the above-mentioned conventional imprinted film having a concavo-convex pattern have a mat-like surface,
The touch felt was slick and rough, and there was no slimy feeling. Therefore, an object of the present invention is to provide a suede-like molded product having a moist, slimy surface.

[0006]

Means for Solving the Problems In order to solve the above-mentioned problems, the molded article of the present invention has an average interval of unevenness of 20 to 20.
50 μm, average surface roughness Ra of unevenness is 0.7 to 2.0 μ
m having a fine uneven layer substantially over the entire surface.
The shape has an average interval of unevenness of 20 to 50 μm and an average of unevenness.
A fine uneven layer having a surface roughness Ra of 0.7 to 2.0 μm was formed.
A shaped film qualitatively having the entire surface, and
Has an uneven layer formed by incorporating a filler
Must be shaped using a shaping film
A molded article having irregularities on the surface characterized by the following.

[0007] In the present invention, the imprint film on which the fine uneven surface is formed, that is, the uneven surface has an average interval of unevenness of 20 to 50 µm and an average surface roughness Ra of 0.7 to 0.7 µm.
By shaping using embossing films with 2.0Myu m, its surface becomes a matte surface with a moist and slime feeling, this feeling is not that with smooth or shiny, yet, Unlike a rough feeling, a molded article having a soft, suede-like smoothness and a certain luxury feeling is obtained.

[0008]

[0009]

According to the present invention, a transfer layer is formed on the shaping film, the film is brought into contact with an object to be transferred, and the transfer layer is transferred to the object to be transferred. The touch of the surface is moist and slimy, and it is soft and smooth like suede.
A molded article to which the transfer layer has been transferred can be obtained. Also,
According to the present invention, it is possible to obtain a press-formed body having fine irregularities on the surface by inserting and molding the shaped film between a pressed product and a formed product which is formed by pressing between heated press plates. Can be. Examples of such a molded body include a melamine decorative board and a DAP decorative board. In order to manufacture a melamine decorative board having irregularities on the surface, a melamine resin-impregnated sheet is laminated on about four phenol resin-impregnated core papers, and an overlay paper impregnated with the melamine resin is further laminated thereon. Insert the molding film between metal plates and insert, for example, 100 kg / cm ² , 1
By performing heating and pressing at 35 ° C for 20 minutes, a melamine decorative board with a soft, smooth, suede-like smooth surface with fine irregularities obtain.

[0011] Further, a DAP decorative plate having irregularities on its surface.
In order to manufacture DAP resin, DAP resin impregnated paper is
Next, stack the mirrors in the same way
Using the shaping film between the surface metal plates, 140
~ 150 ° C, 15kg / cm ^TwoFor about 10 minutes
By doing, the touch touched, moist
Smooth, smooth and suede-like
A kana, a DAP decorative plate having fine irregularities on the surface is obtained.

Next, the present invention uses the above-mentioned imprinting film and irradiates it with ionizing radiation such as ultraviolet rays and electron beams by interposing an ionizing radiation-curable resin between the imprinting film and the substrate. By peeling off the shaping film, an object to be coated having a moist, slimy touch, softness, smoothness like suede, and fine irregularities on the surface is obtained. The method of interposing an ionizing radiation-curable resin between the shaping film and the base material includes applying the ionizing radiation-curable resin to the base material surface in advance, and covering the applied surface with the shaping film, or This is performed by covering the application surface of the shaping film coated with the ionizing radiation curable resin so as to face the substrate surface.

The ionizing radiation-curable resin used in the present invention will be described. The ionizing radiation curable resin includes an electron beam curable resin and an ultraviolet curable resin, and both components are almost the same except that the ultraviolet curable resin contains a photopolymerization initiator and a sensitizer. . Ionizing radiation-curable resins generally contain, as a film-forming component, a polymer, oligomer, monomer or the like having a radical polymerizable double bond in a solution thereof, and, if necessary, a non-reactive polymer. , An organic solvent, a wax and other additives.

The film-forming component used in the ionizing radiation-curable resin used in the present invention is preferably one having an acrylate-based functional group, for example, a relatively low-molecular-weight polyester resin, polyether resin, acrylic resin, or the like. (Meth) of polyfunctional compounds such as epoxy resin, urethane resin, alkyd resin, spiro acetal resin, polybutadiene resin, polythiol polyene resin and polyhydric alcohol
Oligomers or prepolymers such as acrylates and monofunctional monomers such as ethyl (meth) acrylate, ethylhexyl (meth) acrylate, styrene, methylstyrene, N-vinylpyrrolidone and the like as reactive diluents and polyfunctional monomers such as trimethylolpropanetriene (Meth) acrylate, hexanediol (meth) acrylate, tripropylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, pentaerythritol tri (meth) acrylate,
Dipentaerythritol hexa (meth) acrylate,
It contains relatively large amounts of 1,6-hexanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, and the like.

In order to make the above-mentioned ionizing radiation-curable resin into an ultraviolet-curable resin, a photopolymerization initiator is contained therein.
Using a mixture of acetophenones, benzophenones, Michler benzoyl benzoate, α-amyloxime ester, tetramethylthiuram monosulfide, thioxanthone, and n-butylamine, triethylamine, tri-n-butylphosphine, etc. as a photosensitizer Can be. Particularly, in the present invention, polyester acrylate to which diallyl phthalate is added is preferable.

The electron beam curable resin or ultraviolet curable resin used in the present invention may be colored with a coloring agent. The base material to which the ionizing radiation curable resin is applied includes paper,
Various films such as resin sheets, resin films, metal foils,
Sheets; Resin boards; Wood boards such as wood and particle boats;
Inorganic plates such as plaster plates, concrete plates and ceramic plates; metal plates such as iron plates and aluminum plates are used.

On these substrates, a pattern layer,
A colored solid layer may be provided. These ionizing radiation-curable resins can be cured by a usual curing method, that is, by irradiation with an electron beam or ultraviolet rays. For example, in the case of electron beam curing, 50 to 1000 KeV emitted from various electron beam accelerators such as Cockloft-Walton type, Bande graph type, Resonant transformation type, Insulating core transformer type, Linear type, Dynamitron type, High frequency type, Preferably, an electron beam having an energy of 100 to 300 KeV is used, and in the case of ultraviolet curing, ultraviolet rays emitted from light beams such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a xenon arc, and a metal halide lamp can be used. .

Next, in the present invention, the sheet stuck on the base material is impregnated with an unsaturated polyester resin liquid, the above-mentioned imprinting film is coated thereon and cured, and then the imprinting film is peeled off. In this way, a molded article having a moist, slimy feel when touched, and soft, smooth like a suede, and having fine irregularities on the surface is obtained.

Further, according to the present invention, the average interval of the unevenness is 20 to 5
0 .mu.m, the average surface roughness Ra of the uneven 0.7～2.0Myu m
A transfer layer is formed on a shaping film having a fine uneven layer substantially on the entire surface of the surface thereof to form a transfer sheet, and this transfer sheet is preformed by a female mold for injection molding or another mold. Then, injection molding is performed while the preformed transfer sheet is kept in close contact with the female mold for injection molding, and the transfer layer of the transfer sheet is transferred to the molded body. An object of the invention is to obtain a molded product which is soft and has suede-like smoothness and has fine irregularities on the surface.

Further, according to the present invention, the average interval between the irregularities is 20 to 5
0 .mu.m, the average surface roughness Ra of the uneven 0.7～2.0Myu m
The molding film having a fine uneven layer substantially on the entire surface is preformed in a female mold for injection molding or another mold, and the preformed molding film is molded in a female mold for injection molding. Injection molding is performed while keeping the mold in close contact, and by peeling off the molding film, the touch feels soft and slimy, and is soft, smooth like a suede, and fine irregularities on the surface Is obtained.

Further, according to the present invention, the average interval between the irregularities is 20 to
50 μm, average surface roughness Ra of unevenness is 0.7 to 2.0 μ
m, a transfer layer is formed on a molding film having a fine uneven layer substantially all over the surface to form a transfer sheet, and the transfer sheet is placed in a female mold for injection molding, and injection molding is performed. By transferring the transfer layer of the transfer sheet to the molded body, the molded body has a moist, slimy feel, and is soft, smooth like suede, and has fine irregularities on the surface. Is what you get.

In the shaping on the surface of the molded body by the above three types of simultaneous injection molding painting, the transfer sheet or the shaping film to be used may be preformed in advance as described above or may be used without preforming. You can also. When deep drawing is required for the transfer sheet or molding film,
The method of preforming is excellent. In the preforming,
It is performed by a vacuum forming method or a vacuum pressure forming method. These pre-molding methods include a method of directly pre-molding with a mold of an injection molding machine and a method of mounting a pre-formed one with another mold in advance in a female mold for injection molding.

First, a method for directly preforming a transfer sheet or a molding film in a female mold for injection molding will be described. The female mold for injection molding has a structure provided with a vacuum suction hole or the like so as to be applicable to vacuum suction molding. Then, a part of the shape of a molded product formed by injection molding with a male mold is formed. In performing the above preforming, the transfer sheet or the forming film is arranged on the cavity side of the female mold for injection molding mounted on the molding table, and is heated and softened using a heater or the like. The transfer sheet or the forming film is brought into close contact with the cavity surface in the female mold through the vacuum suction hole. Thereafter, the transfer sheet or the shaped film is cooled to complete the preforming of the film.

Next, a method of preforming a transfer sheet or a molding film using a separate mold without using a female mold for injection molding will be described. Using a mold having the same shape as the female mold for injection molding, the transfer sheet or the forming film is heated and softened by an infrared heater or the like, and then formed into the internal shape of the same shape mold by vacuum or vacuum pressure forming. Release mold. The preforming step is completed by mounting the transfer sheet or the shaping film thus formed at a predetermined position of the female mold for injection molding.

After the transfer sheet or the molded film formed by the above preforming is kept in close contact with the female mold for injection molding, the combined sheet is clamped by the male mold for injection molding,
Injection molding is performed by injecting and filling the molded product forming resin melted into the cavity space of both molds through the pouring hole of the male mold. After the injection molding is completed, the male mold is opened, and the plastic molded product is taken out of the mold. Although the transfer sheet or the shaping film is integrally attached to the molded product, the transfer layer of the transfer sheet remains on the molded body side by peeling off the base film of the transfer sheet, and is transferred to the surface. A molded article having fine irregularities is obtained. Also, in the case of a molding film, by removing the molding film from the molded product, fine irregularities are formed on the surface formed on the surface of the molding film.

The shaping film used in the production of each of the above-mentioned molded articles of the present invention is formed of a base film 1 and a concavo-convex layer 2 laminated on the base film 1. In order to prevent the laminated uneven layer 2 from being peeled off from the base film 1 using a PET film as a material of the base film 1, the present invention uses a base film 1 which is subjected to an easy adhesion treatment. It is. In such an easy adhesion treatment, a corona discharge treatment or a known various primer is applied to the surface of the base film 1 or a heat-sensitive adhesive layer is formed.

The uneven layer 2 formed on the base film 1 is formed using a resin composition comprising an inorganic filler and a binder resin. The binder resin is mainly an acrylic polyol crosslinked with a polyisocyanate, and the inorganic fillers are calcium carbonate CaCO ₃ and silica gel SiO ₂ . The addition weight ratio of calcium carbonate to silica gel is 20:10 to 29: 1, and the particle diameter of calcium carbonate, which is a main inorganic filler, is 2 to 5 μm, preferably 3 μm. The average particle size of silica gel is about three times the particle size of calcium carbonate. The silica gel works to adjust the surface roughness of the imprinted film, and when only calcium carbonate is used without adding silica gel, the obtained surface becomes almost flat,
The desired surface cannot be obtained. Silica gel also serves to prevent calcium carbonate from settling.

Examples of the material of the base film 1 of the imprinting film of the present invention include polyester resins such as polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene terephthalate-isophthalate copolymer, polyethylene, polypropylene, and poly (ethylene terephthalate). Polyolefin resin such as methylpentene, polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene,
Polyethylene resins such as ethylene-tetrafluoroethylene copolymer, polyamides such as nylon 6, nylon 66, polyvinyl chloride, vinyl chloride-acetic acid copolymer, ethylene-vinyl acetate copolymer, ethylene vinyl alcohol Copolymers, vinyl copolymers such as polyvinyl alcohol, vinylon, etc., cellulose resins such as cellulose triacetate, cellophane, etc., acrylic resins such as polyethyl methacrylate, polybutyl acrylate, etc., polystyrene, polycarbonate, polyarylate Resin such as high-quality paper, thin paper, glassine paper, and sulfuric acid paper.

The method of applying the uneven layer 2 to the substrate film 1 is performed by a slit reverse coating method. The reason for adopting this coating method is that, in the case of a normal coating method such as gravure coating, the filler particles in the resin composition forming the uneven layer 2 flow like a circle and form streaks on the imprint film. It is because. Therefore, in the present invention, in order not to form such streaks, the coating method is applied by a slit reverse coating method shown in FIG. FIG. 3 shows an outline of the slit reverse coating method. The resin composition discharged from the nozzle coating device 4 is applied to the base film 1 running on the backup roll 6, and then coated by the squeeze roll 5 with the coating thickness regulated.

Further, the imprinting film used in the present invention is one in which a release agent is contained in the uneven layer 2.
As the release agent, silicone, fluorine resin, various waxes and the like are used. The shaping film is used for the base film 1 of the transfer sheet, and a release agent is contained in a release layer composed of the uneven layer 2 on the base film 1. In the transfer sheet using such a shaping film 1 and forming a transfer layer on the shaping film, the transfer layer is formed on a release layer on the base film 1. When the transfer is performed, the transfer layer easily moves to the transfer target. The release material must be designed not to bleed much on the surface in consideration of compatibility with the binder resin. If there is a large amount of bleed on the surface, unevenness occurs in the uneven layer 2 of the molding film. In order to eliminate such unevenness, a combination having good compatibility with the binder resin for forming the uneven layer 2 is important. For example, when acrylic polyol is used for the binder resin, an amino-modified silicone oil having good compatibility with the polyol is used. On the other hand, if the amount of the release agent is too small, the peeling becomes heavy, and if the amount is too large, the adhesion between the resin for forming the concavo-convex layer and the base film 1 is reduced. 5% by weight is good.

[0031]

Example 1 An inorganic filler was formed by mixing calcium carbonate CaCO ₃ having a particle size of ₃ μm and silica gel SiO ₂ having a particle size of 10 μm at a weight ratio of 28: 2. Next,
A binder resin was composed of 100 parts by weight of acrylic polyol and 8.5 parts by weight of polyisocyanate.

A resin composition for forming a concavo-convex layer was prepared using 52 parts by weight of the inorganic filler, 48 parts by weight of the binder resin, and 4 parts by weight of an amino-modified silicone oil as a release agent. This resin composition was coated on a PET film (manufactured by Diafoil Co., Ltd .: TE, trade name, thickness: 38 μm) which had been subjected to easy adhesion treatment by a slit reverse coating method so as to have a thickness of 15 μm (dry film thickness). After drying at 110 ° C. for 30 seconds, aging was performed at 60 ° C. for 3 days.

The average surface roughness Ra of the surface of the shaped film thus obtained was 1.2 μm. Further, the maximum height difference between the projections and the depressions is 8.0 μm, and the average interval between the projections and depressions is 30 μm.
m, the average inclination angle of the irregularities was 14 °. Where average
The inclination angle is, as shown in FIG.
when the _{h 1, h 2, h 3} ~h n, the following equation (1)
It means θa represented by the equation.

(Equation 1) The reason why the PET film subjected to the easy-adhesion treatment was used as the base film used for the shaping film in Example 1 is because the adhesion to the uneven layer adhered on the base film was good. .

An ultraviolet-curable resin (manufactured by Dainichi Seika Kogyo Co., Ltd .: Seika Beam, trade name) is placed on the shaping film.
0 μm (dry film thickness), and an acrylic adhesive as an adhesive layer was applied thereon,
One transfer lamp of W / cm was irradiated at 20 m / min to obtain a transfer sheet. Next, using this transfer sheet, transfer was carried out on an ABS sheet by a hot roll transfer machine to obtain a transfer body having fine irregularities formed on the surface.

The surface of the transfer body thus obtained is
Ra is exactly the same as the surface shape of the transfer film used.
2 μm, the maximum height difference between the projections and the depressions was 8.0 μm, the average interval between the projections and depressions was 30 μm, and the average inclination angle of the projections and depressions was 14 °.

[0036]

Example 2 A melamine resin-impregnated sheet was placed on about 4 sheets of phenol resin-impregnated core paper, and 35 g / m ² was further placed thereon.
Laminate impregnated with melamine resin on overlay paper, sandwiched between two mirror-finished metal plates, and inserted the imprinting film manufactured in Example 1 having irregularities on the surface,
By heating and pressing at 100 kg / cm ² and 135 ° C. for 20 minutes, a melamine decorative board having fine irregularities formed on the surface was obtained.

The surface of the melamine decorative board thus obtained has an R.R.
a is 1.2 μm, and the maximum height difference between the convex portion and the concave portion is 8.0 μm.
m, average interval of unevenness is 30 μm, average inclination angle of unevenness is 1
What was 4 ° was obtained.

[0038]

Example 3 DAP resin-impregnated paper is sequentially stacked on a plate-like substrate, and the shaped film manufactured in Example 1 is sandwiched between mirror-finished metal plates in the same manner as in the method for manufacturing a melamine decorative board in Example 2. 140-150 ° C, 15 kg / c using
as m ^2, 10 minutes, heating was performed for pressing.

The surface of the decorative DAP board obtained in this manner had the same Ra Ra shape as that of the imprinted film used.
Is 1.2 μm, the maximum height difference between the convex portion and the concave portion is 8.0 μm,
The average spacing of the irregularities is 30 μm, and the average inclination angle of the irregularities is 14 °
Is obtained.

[0040]

Example 4 A pattern was printed on a polyvinyl chloride sheet having a thickness of 0.25 m / m, and a UV curable resin (manufactured by Dainichi Seika Kogyo Co., Ltd .: Seika Beam, trade name) was coated to 50 μm (dry film thickness). ), And a shaped film prepared as follows was laminated. That is, this imprinting film was formed by applying the resin of Example 1 to a 30-μm-thick easily-adhered PP film (Tocello; OP-Z) so as to have a dry film thickness of 15 μm, and then at 100 ° C. for 30 seconds. After drying, it was aged at 60 ° C. for 3 days to obtain a shaped film. 80 W /
After irradiating one lamp of 20 cm / min at 20 m / min, the shaping film was peeled off to obtain a sheet-like material having fine irregularities formed on the surface.

The surface of the sheet-like material thus obtained had the same Ra as the surface shape of the imprinting film used, having a Ra of 1.2 μm, a maximum height difference between the projections and the depressions of 8.0 μm, and an uneven surface. One having an average interval of 30 μm and an average inclination angle of the irregularities of 14 ° was obtained. In addition, in Example 4, a polypropylene film was particularly used as the base film used for the imprinting film for the following reason. The PET film used in each of the above-described embodiments absorbs light when irradiated in a wavelength region of 365 nm or less, and thus has a disadvantage of insufficient curing when curing the ultraviolet curable resin coating film. On the other hand, a polypropylene film is superior to a PET film in transmittance in a wavelength region of 200 nm or more, and a mercury lamp having a wavelength of about 254 nm or more is usually used for ultraviolet irradiation. For curing, it is preferable to use a polypropylene film having excellent transmittance at 365 nm.

FIG. 4 is a graph showing the transmittance of the PET film and the polypropylene film at various wavelengths. From FIG. 4, it can be seen that the polypropylene film shows an excellent transmittance in the region of 200 to 365 nm as compared with the PET film.

[0043]

Embodiment 5 Plywood Printed Paper (Titanium Paper 60-100g)
Is applied with an emulsion adhesive, a polyester resin (BPO added as a catalyst) is applied thereon, and the same imprinting film as the imprinting film used in Example 4 is laminated thereon and left at room temperature for 24 hours. . Thereafter, the molding film was peeled off to obtain a molded body.

The surface of the sheet thus obtained had the same Ra as the surface shape of the imprinting film used, Ra of 1.2 μm, the maximum height difference between the projections and the depressions of 8.0 μm, and the unevenness of the irregularities. One having an average interval of 30 μm and an average inclination angle of the irregularities of 14 ° was obtained.

[0045]

[Embodiment 6] In this embodiment 6, a transfer sheet manufactured by providing a pattern layer on the layer to be transferred in the transfer sheet of the above-mentioned embodiment 2 is used. Then, this transfer sheet is transferred to an injection molded body by a molding method (thermoject molding method) in which the vacuum forming step and the injection molding step of the insert molding method are docked.

FIG. 5 is a sectional view showing the layer structure of the transfer sheet used in the sixth embodiment. 1 is a substrate film, 2 is an uneven layer provided on the substrate film,
And the concavo-convex layer 2 constitute a shaping film. 7
Is a transfer layer formed on the uneven layer 2 side of the shaping film,
8 is a picture layer printed on the transfer layer 7 by printing ink,
Reference numeral 9 denotes an adhesive layer provided on the entire surface on the side where the picture layer 8 is formed.

The transfer sheet used in Example 6 was manufactured as follows. An ultraviolet curable resin (manufactured by Dainichi Seika Kogyo Co., Ltd .: Seika Beam, trade name) was applied on the imprinted film manufactured in Example 1 so as to have a thickness of 10 μm (dry film thickness). On this, the picture layer 8 was provided by printing ink. Further, an acrylic adhesive was applied thereon as an adhesive layer 9, and one lamp of ultraviolet light 80 W / cm was irradiated at 20 m / cm.
The transfer sheet was obtained by irradiating the transfer sheet at a minimum speed.

Next, the transfer sheet was used to transfer to an injection-molded body by the simultaneous painting method of injection molding to obtain a molded body having irregularities on the surface as follows. The transfer sheet was heated by a heater and softened. Next, the transfer sheet was moved, and vacuum molding was performed by a female mold having vacuum holes of an injection molding machine having a vacuum pump. Next, while the transfer sheet vacuum-formed was kept in close contact with the female mold, a resin was injected from a male mold of an injection molding apparatus to perform injection molding.
The mold was opened and the base sheet of the transfer sheet was peeled off to obtain an injection molded product. The surface of the injection-molded article obtained in this way had a Ra of 1.2 μm, a maximum height difference between the projections and the depressions of 8.0 μm, an average interval of the irregularities of 30 μm, and an average inclination angle of the irregularities of 14 °. Was.

[0049]

[Embodiment 7] In the present embodiment 7, in the molding method (thermoject molding method) in which the vacuum forming step and the injection molding step of the insert molding method of the above-mentioned embodiment 6 are docked, the transfer sheet is manufactured in the embodiment 1 instead. It is an example using a shaped sheet. A molded article having irregularities on the surface of the injection molded article was obtained in the following manner by using the shaping sheet and performing simultaneous injection molding and painting.

The shaped sheet obtained in the intermediate process of Example 1 was heated by a heater to soften it. Next, the shaping sheet was moved, and vacuum molding was performed by a female mold having vacuum holes of an injection molding machine having a vacuum pump.
Next, a resin was injected from a male mold of an injection molding apparatus while the vacuum-formed molding sheet was kept in close contact with the female mold, and injection molding was performed. The mold was opened and the molded sheet was peeled off to obtain an injection molded product. The surface of the injection-molded article obtained in this way had a Ra of 1.2 μm, a maximum height difference between the projections and the depressions of 8.0 μm, an average interval of the irregularities of 30 μm, and an average inclination angle of the irregularities of 14 °. Was.

[0051]

Eighth Embodiment In an eighth embodiment, the same transfer sheet as that used in the sixth embodiment is used, and in-mold transfer is performed. The same transfer sheet as that used in Example 6 was positioned by a sensor so as to come to a predetermined position of a female mold of an injection molding apparatus. Next, the mold was clamped and injection molding was performed. The mold was opened, the base sheet of the transfer sheet was peeled off, and an injection molded product on which the transfer layer of the transfer sheet was transferred was obtained. The surface of the injection molded article thus obtained has a Ra of 1.2 μm and a maximum difference in height between the convex and concave portions of 8.8.
The average interval between the irregularities was 0 μm, the average interval between the irregularities was 30 μm, and the average inclination angle of the irregularities was 14 °.

[0052]

Embodiment 9 In contrast to Embodiment 4 in which an ionizing radiation-curable resin is applied to a substrate, Embodiment 9 applies an ionizing radiation-curable resin to a molding film. This is an example in which fine irregularities are formed on the surface of a base material. An aluminum substrate for a window frame material, which was formed by profile extrusion, was prepared.
On the other hand, the same coating material obtained by adding a coloring pigment to the same ultraviolet curable resin as in Example 4 was applied on a mat surface on the same shaping film as in Example 4 using a roll coater so that the coating amount when dried was 20 g / m ^2. Coated. Next, the coated surface is brought into close contact with the aluminum substrate, and ultraviolet rays are irradiated at a strength of 160 W / cm for 5 minutes.
Irradiation was performed at a speed of m / min to cure the ultraviolet curable resin. Next, the shaping film was peeled off to obtain an aluminum sash frame having fine irregularities formed on the surface. The surface had an Ra of 1.2 μm, a maximum height difference between the projections and the depressions of 8.0 μm, an average interval between the projections and depressions of 30 μm, and an average inclination angle of the projections and depressions of 14 °.

[0053]

Example 10 Colored polyvinyl chloride (Almic: trade name, manufactured by Dainichi Seika Kogyo Co., Ltd.) was coated on the aluminum base material of Example 9 with a gravure coat to a thickness of 100 μm and dried. Thus, a colored aluminum substrate was obtained.
On the other hand, the same UV curable resin as in Example 4 was used, and the UV curable resin was made transparent without adding a coloring pigment, except that the resin was transparent. A transparent layer was provided on an aluminum substrate, and fine irregularities were formed on the surface. The surface has an Ra of 1.2.
μm, the maximum height difference between the projections and the depressions was 8.0 μm, the average interval between the projections and depressions was 30 μm, and the average inclination angle of the projections and depressions was 14 °.

[0054]

As described above in detail, according to the present invention, the surface of the molded article is formed such that the average interval between the irregularities is 20 to 50 μm,
By average roughness Ra of the irregularities and 0.7～2.0Myu m, its surface could be obtained a matt surface with a moist and slime feeling. The feel was not slippery or shiny, but instead of a grainy feel, it was soft, suede-like smooth, and had some sort of luxury.

[Brief description of the drawings]

FIG. 1 shows a shaping film used in the present invention.

FIG. 2 is a diagram for explaining an average inclination angle of unevenness.

FIG. 3 shows a slit reverse coating method used in the present invention.

FIG. 4 is a graph showing the transmittance of a PET film and a polypropylene film at various wavelengths.

FIG. 5 shows a layer structure of a transfer sheet used in Example 6.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 base film 2 uneven layer 4 nozzle coating device 5 squeeze roll 6 backup roll 7 transfer layer 8 picture layer 9 adhesive layer

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI // B29L 7:00 (72) Inventor Ichiro Taki 1-1-1, Ichigaya-Kagacho, Shinjuku-ku, Tokyo Inside Dai Nippon Printing Co., Ltd. (72) Inventor Yasuhiro Ikeda 1-1-1, Ichigaya-Kaga-cho, Shinjuku-ku, Tokyo Inside Dai Nippon Printing Co., Ltd. (72) Inventor Yu Shida 1-1-1-1, Ichigaya Kaga-cho, Shinjuku-ku, Tokyo Inside Dai Nippon Printing Co., Ltd. 56) References JP-A-62-111720 (JP, A) JP-A-1-192600 (JP, A) JP-A-1-51174 (JP, A) JP-A-50-130855 (JP, A) JP-A-2-14111 (JP, A) JP-A-4-82736 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 59/00-59/18 B32B 1/00-35 / 00 B44C 1/00-1/28

Claims (5)

(57) [Claims] 1. A molded article having a fine uneven layer having an average interval of unevenness of 20 to 50 μm and an average surface roughness Ra of 0.7 to 2.0 μm on substantially the entire surface thereof, An imprint film having an average interval of 20 to 50 μm, an average surface roughness Ra of irregularities of 0.7 to 2.0 μm on a substantially entire surface of a fine irregular layer, and containing a filler. A molded article having irregularities on the surface, characterized in that the molded article has been molded using a molding film having a formed uneven layer. 2. A transfer sheet is formed by forming a transfer layer on the shaping film using the shaping film according to claim 1, and bringing the transfer sheet into contact with an object to be transferred. A molded article having irregularities on the surface, obtained by transferring the same to the transfer object. 3. The shaping film according to claim 1,
A press-formed body having irregularities on its surface, characterized in that it is obtained by being inserted between a press plate and a formed product which is formed by pressing between heated press plates. 4. The press-formed body having irregularities on its surface according to claim 3, wherein the press-formed body is a melamine decorative board. 5. The press-formed body according to claim 3, wherein the press-formed body is a decorative DAP plate.