JP3200785B2 - Manufacturing method of plastic molded products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the improvement of the design of a plastic molded product used for a building interior, a door, a living room and the like, and more particularly to a method for producing a plastic molded product having a deep pattern. is there.

[0002]

2. Description of the Related Art Conventionally, with respect to the improvement of the design of plastic molded products, for example, a molded product having a decorative sheet adhered to the surface thereof, a molded product having fine embosses formed on the surface thereof, called fine embossing, There are those in which a pattern is transferred to the surface of a molded product at the same time as molding or a pattern sheet is integrated. However, in each case the design is superficial,
No deep expression was obtained.

[0003]

DISCLOSURE OF THE INVENTION The present invention is intended to improve the above-mentioned drawbacks associated with decoration of the surface of a plastic molded product , and to produce a plastic molded product having a higher design and expressing a deeper pattern. The aim is to provide a method .

[0004]

Means for Solving the Problems In view of the above objects, the present invention has been completed by the following method as a result of various studies. That is, the invention of claim 1 is transparent.
Or one side of a translucent film layer
Has a textured pattern due to curing resin or thermosetting resin
Sheet layer of ionizing radiation curable resin or thermosetting resin
After forming and curing this, the laminated sheet is injection molded
Arranged in the mold so that the uneven pattern surface faces the injection resin side
After that, the resin is injected,
Manufacturing plastic molded products characterized by
Law, consisting of

[0005] Further, the invention of claim 2 is the method of manufacturing a plastic molded article according to the invention of claim 1, wherein the resin forming the plastic molded article layer contains a glitter powder or a pearl pigment. Features.

Next, the present invention will be described in detail with reference to the drawings. FIG. 1 is a schematic sectional view showing the structure of a plastic molded product obtained by the production method of the present invention. That is, the plastic molded product obtained by the production method of the present invention is, in order from the surface, a transparent or translucent film layer 1, a sheet layer of an ionizing radiation-curable resin or a thermosetting resin having an uneven pattern formed on one surface. 2. A plastic molded product having a structure in which the plastic molded body layer 3 is laminated and integrated, with the uneven pattern surface of the sheet layer 2 of ionizing radiation-curable resin or thermosetting resin facing the plastic molded body 3 side. It is characterized by having done.

FIG. 2 shows an apparatus of a known drum printing system (hereinafter abbreviated as DPS). In a plastic molded product obtained by the production method of the present invention, one of transparent or translucent film layers 1 is formed. On the surface,
It is explanatory drawing of the process of laminating | stacking, forming the sheet layer 2 of the ionizing radiation hardening type resin or the thermosetting type resin which has an uneven | corrugated pattern. That is, when an ultraviolet-curable resin is used as the ionizing radiation-curable resin, an ultraviolet-curable resin liquid is supplied from a coating liquid supply device 12 to an intaglio roll 11 for forming an uneven pattern, and a transparent or semi-transparent resin is supplied thereon. Are laminated and pressed by a pressing roll 13. Subsequently, the transparent or translucent film 1 is irradiated with ultraviolet light from above the transparent or translucent film 1 on the intaglio roll to cure the ultraviolet-curable resin liquid, and is laminated and integrated with the transparent or translucent film. Thereafter, the laminate sheet is peeled off from the intaglio roll via the peeling roll 15 to obtain a laminated sheet having an uneven pattern on the surface.

FIG. 3 shows a state in which a laminated sheet prepared by the above-mentioned DPS method and having an uneven pattern on its surface is inserted and arranged in an injection molding die with the uneven pattern surface of the sheet facing the injection resin side. It is a schematic cross section of the mold part shown. A resin molded product is obtained by injecting the heated and melted resin into the thus-prepared mold, cooling and solidifying the resin. In addition, it is preferable that the surface of the mold used for placing the laminated sheet be a relatively flat surface or a quadratic curved surface. In the case of a cubic curved surface, there is no problem with a light curved surface, but a deep curved surface can be prepared by preforming a sheet, but there is a limit.

Production of the plastic molded article of the present invention is described below.
Materials used for the method will be described. (Transparent or translucent film layer) The film used for this layer is located at the outermost layer when finished into a plastic molded product, and the performance required for the film varies to some extent depending on the use of the molded product. it is conceivable that.
However, from the manufacturing process of the molded article, those having high film strength and excellent heat resistance are preferable, and there is no particular limitation as long as they have at least these two performances. Specific examples include, for example, films of polyethylene phthalate, polyacrylate, polyether ketone, polyimide and the like.

(Ionizing radiation curable resin or thermosetting resin) As the ionizing radiation curable resin, known ultraviolet ray and electron beam curable resins can be used. That is, a composition in which a prepolymer, an oligomer, and / or a monomer having a polymerizable unsaturated bond or an epoxy group in a molecule is appropriately mixed is used. As the resin system, for example, urethane acrylate, polyester acrylate, epoxy Examples include acrylate such as acrylate, silicon resin such as siloxane, polyester, and epoxy. Among them, it is preferable to use an acrylate such as an epoxy acrylate or a silicone acrylate, or a high crosslink density type having a polyfunctional monomer such as a siloxane as a main component.

When these are used as an ultraviolet curable resin, a known photopolymerization initiator may be added. For example, acetophenones, benzophenones, Michler benzoyl benzoate, α-amyloxime ester,
There are tetramethylmeuram monosulfide, thioxanthones, and n-butylamine as a photosensitizer;
Triethylamine, tri-n-butylphosphine and the like can be used as a mixture.

Further, a thermosetting resin is used in the production method of the present invention.
Here , it can also be used as a material for forming a resin layer having an uneven pattern. In this case, it may be appropriately selected from known thermosetting resins, for example, diallyl phthalate resin, unsaturated polyester resin, polyurethane resin, epoxy resin, amino alkyd resin, silicon resin,
Polysiloxane resin, melamine resin, phenol resin,
Urea resins, guanamine resins, melamine-urea co-condensation resins and the like can be mentioned. These may be used by adding a curing agent such as a crosslinking agent and a polymerization initiator, a polymerization accelerator, a solvent, a viscosity modifier, an extender, and the like, as necessary.

As described above, in the manufacturing method of the present invention, as the material for forming the resin layer having a concavo-convex pattern, an electron beam-curable resin, an ultraviolet-curable resin, and a thermosetting resin have been mentioned. It is possible to precisely form the uneven pattern on the surface of the intaglio roll 11 shown in FIG. 2 on the sheet, and even if the resin is injection-molded on the uneven pattern surface in a later step, the pattern is deformed or collapsed. There is no advantage.

The type of the concavo-convex pattern used here may be freely selected, and the use of the molded article such as a lattice, a polka dot-like pattern or an abstract pattern, or a group of curves and straight lines such as a waveform and a combination thereof. Any suitable design can be used. Also, the height of the unevenness is not particularly limited, and may be freely formed in the range of 0.5 μm to 300 μm.

As for the ionizing radiation irradiating device in the DPS process, an electron beam irradiating device is used when an electron beam curable resin is used, and an ultraviolet irradiating device and a thermosetting resin are used when an ultraviolet curable resin is used. In the case of (1), it is necessary to properly use each of them, such as a heating device.

(Plastic molded article layer) The resin used for the plastic molded article layer in the method for producing a plastic molded article of the present invention can be freely selected depending on the use of the molded article, as long as it is a resin that can be injection molded. However, styrene resins such as polystyrene and ABS, which are widely used,
Olefin resins such as polyethylene and polypropylene,
In addition, there are acrylic resins, polycarbonates, polyarylates, and the like, which can be used in the present invention.

(Glitter powder or pearl pigment) In the invention of claim 2, in order to enhance the visual effect of the concavo-convex pattern formed of the ionizing radiation-curable resin or the thermosetting resin, it is used as a lower layer thereof. forming the plastic molded body layer
Resin containing brilliant powder or pearl pigment. For example, aluminum powder,
Metal powders such as copper powder and brass powder, metal flakes, or powders having a metallic luster such as cut pieces of plastic film on which metal is deposited are used. Pearl pigments include titanium dioxide-coated mica, fish scale foil, acid Pigments having pearl luster or interference luster such as bismuth chloride can be used.

[0018]

The plastic molded article according to the production method of the first aspect of the present invention comprises, in order from the surface, a transparent or translucent film layer, an ionizing radiation-curable resin having an uneven pattern formed on one surface, or In a plastic molded product in which a thermosetting resin sheet layer and a plastic molding layer are laminated and integrated, the uneven pattern surface of the ionizing radiation curing resin or thermosetting resin sheet layer is laminated and integrated toward the plastic molding side. It is a thing. For this reason, the uneven surface is viewed through the transparent or translucent film layer and the sheet layer of the ionizing radiation-curable resin or the thermosetting resin. Can be added.

The plastic molded article according to the production method of the second aspect of the present invention is obtained by adding a glitter powder or a pearl pigment to a resin forming a plastic molded body layer. For this reason, the depth of the reflected light pattern in which the concavo-convex pattern obtained by the manufacturing method according to the first aspect of the present invention is developed,
The three-dimensional effect can be further emphasized, and a feeling of metallic luster, pearl luster or interference luster can be added.

[0020]

The present invention will be described below in detail with reference to examples. (Example 1) As a transparent or translucent film layer as the outermost layer, a single-sided easy-adhesion polyethylene terephthalate film (A-4100 manufactured by Toyobo) having a thickness of 100 µm was used. UV-curable urethane acrylate composition PE as resin
Using X-808-1 (Dainichi Seika)
It was applied and cured by the DPS method of FIG. 2 using an intaglio roll (precision embossing plate) provided with a 150 μm abstract pattern, thereby producing a transparent laminated sheet having an uneven abstract pattern on the surface. The ultraviolet irradiation was performed using a high-pressure mercury lamp of 160 W / cm and two lamps at a line speed of 20 m / min.

Next, the laminated sheet obtained by the above-mentioned DPS method is placed in an injection molding die with the uneven surface facing the injection resin, and ABS resin (KU-600 manufactured by Sumitomo Dow) is injected by a conventional method. Then, they were integrated to obtain a molded product of Example 1.
The abstract pattern on the surface of this plastic molded product has a depth, and a molded product with a high design that has never existed before has been obtained.

(Example 2) In the structure of the plastic molded article of Example 1, AB used for the plastic molded article layer
Only the S resin (KU-600, manufactured by Sumitomo Dow) was replaced with a resin in which 1% by weight of a pearl pigment (manufactured by Nikko Bix) was kneaded and dispersed with respect to the same resin.
A plastic molded product of Example 2 was obtained with the same configuration and processing method as described above. The abstract pattern on the surface of this molded product increases sharpness with depth, and adds a pearly luster,
Higher design plastic molded products were obtained.

(Comparative Example 1) In the configuration of the plastic molded article of Example 1, when the laminated sheet obtained by the DPS method is put into the injection mold, the uneven surface is in contact with the mold, that is, the uneven surface. Was disposed so as to come out of the outermost surface of the molded product, and the other conditions were the same as in Example 1 to obtain a plastic molded product of Comparative Example 1. The surface of this molded product was similar to an abstract pattern formed by ordinary precision embossing, and had a feeling of irregularities, but had a somewhat monotonous finish without depth.

[0024]

As described above, the plastic molded article produced by the method of the present invention according to the first aspect of the invention has a transparent or translucent film layer and an ionizing radiation having an uneven pattern formed on one surface in order from the surface. In a plastic molded product in which a sheet layer of a curable resin or a thermosetting resin and a plastic molded body layer are laminated and integrated, the uneven pattern surface of the sheet layer of the ionizing radiation curable resin or the thermosetting resin is formed on the plastic molded body side. It is laminated and integrated for the purpose.
By adopting such a configuration, it is possible to express a deep uneven pattern even though the surface is smoother than a molded article having a rough pattern on the surface, and to achieve an unprecedented high design property This has the effect of obtaining a plastic molded product of

The plastic molded article according to the production method of the second aspect of the present invention is obtained by adding a glitter powder or a pearl pigment to a resin forming a plastic molded body layer. By adopting such a configuration, it is possible to express the depth and three-dimensional effect of the concavo-convex pattern obtained by the configuration of the first aspect of the invention more sharply, and to add a feeling of metallic luster, pearl luster or interference luster. Thus, an effect of obtaining a plastic molded product having extremely high designability is achieved.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing a configuration of an embodiment of a plastic molded product according to a production method of the present invention.

FIG. 2 shows a plastic molded article produced by the method of the present invention, in which a sheet layer of an ionizing radiation-curable resin or a thermosetting resin having an uneven pattern is provided on one surface of a transparent or translucent film layer. Laminate while forming (D
It is explanatory drawing of a (PS) process.

FIG. 3 is a view showing a state in which a laminated sheet having an uneven pattern formed on the surface is inserted and arranged in an injection molding die with the uneven pattern surface of the sheet facing the injection-molded resin side; FIG. 3 is a schematic cross-sectional view of a mold part showing the above.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Transparent or translucent film layer 2 Sheet layer of ionizing radiation curable resin or thermosetting resin having an uneven pattern formed on its surface 3 Plastic molded body layer 11 Intaglio roll 12 Coating liquid supply device 13 Press roll 14 a, 14 b Ionizing radiation Irradiation device 15 Peeling roll

Continuation of front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B32B 1/00-35/00

Claims (2)

(57) [Claims] 1. One of transparent or translucent film layers
On the surface, use ionizing radiation curable resin or thermosetting resin.
Ionizing radiation-curable resin with irregular pattern
After forming a sheet layer of curing resin and curing it,
The uneven surface of the laminated sheet in the injection mold is on the injection resin side
After injecting the resin,
Plus, characterized by being laminated and integrated with the back molded layer
Method of manufacturing tic molded products. 2. The method for producing a plastic molded product according to claim 1, wherein a glitter powder or a pearl pigment is contained in a resin forming the plastic molded body layer .