JP3514562B2 - Method for producing low-reflection insert molded product having open window and low-reflection insert film - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention has a pattern having a transparent window part formed on a transparent plastic panel, and displays the light of a fluorescent tube light emitter disposed behind and characters and images on a liquid crystal display. The present invention relates to a method for manufacturing a low-reflection insert molded product having a window part that can be seen through the window and a low-reflection insert film used in the manufacturing method. Examples of products specifically manufactured by the present invention include front panels such as audios, televisions, and washing machines, or automobile meter panels and audio panels.

[0002]

2. Description of the Related Art In a product having a conventional window part, room light, natural light, etc. are reflected on the surface of the window part and the window part shines brightly, and the light from the light emitting body behind the plastic panel and the liquid crystal display can be seen. There is a problem that it becomes difficult. In order to eliminate this problem, anti-reflection processing is applied to the surface of the window. As a conventional example of anti-reflection processing, there is (1) a surface of a plastic panel corresponding to a window part is roughened by etching. (2) There is one in which a plastic panel is placed in a vacuum vapor deposition apparatus, and a metal thin film made of a low refractive index material is formed on the surface of the plastic panel corresponding to a window portion by vacuum vapor deposition or the like. It is used for lenses, car rearview mirrors, CRT screens, etc.

[0003]

However, in the antireflection processing of (1), if the roughness of the rough surface of the plastic panel is increased in order to improve the antireflection effect, the window part becomes white or becomes opaque. The transparency becomes low, and it becomes difficult to see the light of the fluorescent tube light emitter disposed behind and the characters and images on the liquid crystal display. On the other hand, if the roughness of the rough surface is reduced to increase the transparency of the draft window, the antireflection effect is diminished. Thus, it was difficult to achieve both the antireflection effect and the improvement of the transparency of the window.

In the antireflection processing of (2), in the case of a three-dimensionally shaped plastic panel, there are portions near or far from the vapor deposition source, or portions where vaporized metal does not reach, The thickness of the metal thin film varies depending on each part of the plastic panel, and the antireflection effect varies. Further, it is necessary to evacuate the inside of the vacuum vapor deposition device every time the plastic panel is replaced, which takes much labor and time, and the production efficiency is very poor.

Further, in any of (1) and (2),
Since the step of obtaining the plastic panel and the step of antireflection processing are performed separately, the production efficiency was very poor.

An object of the present invention is to provide a method for producing a low-reflection insert molded article capable of efficiently producing a plastic panel or the like having an anti-reflection effect in a window portion, sufficient transparency, anti-reflection effect and surface strength. Another object of the present invention is to provide a low-reflective insert film used for producing a low-reflective insert-molded product having a cutout window portion which does not cause variations in antireflection effect even if it has a three-dimensional shape.

[0007]

In order to achieve the above-mentioned object, the low reflection insert film of the present invention comprises, as described in claim 1, a transparent substrate sheet comprising a metal thin film on one surface thereof. The reflective layer was formed, and the low reflective insert film in which the pattern layer having the window portion on the other surface and the transparent adhesive layer were sequentially formed was obtained.

Further, as described in claim 2, a first low reflection layer made of a metal thin film is formed on one surface of the transparent substrate sheet, and a second low reflection layer made of a metal thin film is formed on the other surface.
A low-reflection insert film in which a pattern layer having a window portion and a transparent adhesive layer were sequentially formed.

Further, as described in claim 3, in the low reflection insert film according to claim 1 or 2, a low reflection insert film in which one surface or both surfaces of the transparent base sheet is an uneven surface. .

A method of manufacturing a low reflection insert molded product having a cutout window portion according to the present invention is as described in claim 4.
After arranging the low reflection insert film according to any one of claims 1 to 3 in a mold for injection molding and closing the mold, a transparent molten resin is injected into the mold on the adhesive layer side of the low reflection insert film. Then, by solidifying the molten resin, the low-reflective insert film was adhered to the transparent resin molded product to manufacture a low-reflective insert molded product having a cutout window.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below with reference to the drawings. The low reflection insert film of the present invention will be described first (FIGS. 1 to 3).

The insert film of the present invention comprises at least a transparent substrate sheet 1, a low reflection layer 2 made of a metal thin film, and a pattern layer 3 having a window. If necessary, one or both surfaces of the base sheet 1 may have an uneven surface 6
May be

The material of the base sheet 1 is polyethylene terephthalate resin, polycarbonate resin, polypropylene resin, nylon resin, vinylon resin, acetate resin, polyethylene resin, polyamide resin, polyester resin, polyacrylic resin, polychlorinated resin. Use a transparent resin sheet such as vinyl resin. The base sheet 1 may have a thickness of 21 μm to 300 μm. The uneven surface 6 means that the surface of the base sheet itself is made uneven by etching or sandblasting, or that an ink layer mixed with an extender pigment such as silica is formed on the surface of the base sheet by printing or coating. (Figure 3).

The low reflection layer 2 is a layer that scatters reflection of light. The low reflection layer 2 is made of a metal material such as metal, metal oxide, metal fluoride, metal halide, metal nitride, and metal sulfide, and is vacuum-deposited, sputtered, or ion-plated (hereinafter referred to as “metal vapor deposition, etc.”). It is formed as a metal thin film by a method such as ". The vacuum deposition is a method of evaporating a metal in a vacuum of about 0.0001 torr to solidify a metal thin film of about 1 μm on the surface of an object to be deposited. Sputtering is a type of vacuum deposition, in which nitrogen and argon gas are sent between both electrodes of an anode and a cathode in a vacuum of about 0.001 Torr, and a high voltage of 1,000 to 20,000 volts is applied between both electrodes to cause glow. It is a method of discharging and cationized gas molecules knock out the atoms of the cathode metal and deposit the metal ionized atoms on the object to be sputtered to form a metal thin film. What is ion plating?
A method in which a DC voltage of several thousand volts is applied between the object to be plated and the molten metal in a vacuum, and the vaporized metal is ionized and is attracted to the back side by the voltage difference to form a metal thin film with excellent adhesion. . In order to form a metal thin film on the base sheet 1, the base sheet is sent out from a roll of the base sheet that is wound into a roll, and is passed through a vacuum vapor deposition device or the like to form a metal thin film, and then the roll is rolled again. It is rolled up into a shape.

The low reflection layer 2 may be a single layer or a plurality of layers.
The film thickness of the low reflection layer 2 is such that visible light can be prevented from being reflected. When the low reflection layer 2 has a four-layer structure, the first layer has a thickness of 0.05 to 0.15λ, and the second layer has a thickness of 0.05 to, when the design wavelength is λ, in the range of 450 to 550 nm. 0.15λ, the third layer is 0.36 to 0.49
λ, the fourth layer has a thickness of 0.15 to 0.35λ. Low reflective layer 2
When it is composed of a plurality of layers, the metal thin film having a high refractive index and the metal thin film having a low refractive index may be sequentially laminated from the side of the base sheet 1. As the high refractive index metal thin film, titanium oxide,
For example, zirconium oxide. Examples of the metal film having a low refractive index include magnesium fluoride and lithium fluoride.
Examples of metals used for vacuum deposition include chromium, titanium, aluminum, tin and nickel. Examples of metal oxides used for vacuum vapor deposition include silicon monoxide, silicon dioxide, indium oxide, titanium oxide, and indium tin oxide.

The picture layer 3 represents characters, numbers, figures, symbols, patterns, etc. formed on the front surface of, for example, a front panel of an audio system, a television, a washing machine or the like, or a meter panel of a car or an audio panel. It is a layer to do. The pattern layer 3 is formed by using an ink composed of a resin binder and a pigment or a dye. The pattern layer 3 may be formed using an ink composed of a resin binder and a metal pigment or an inorganic pigment having a hiding property such as a pearl pigment or a stain. The pattern layer 3 has at least a transparent window portion 31 (FIGS. 1 to 3). The window portion may be formed of a colorless transparent ink, or may be formed of an ink whose pigment concentration is low enough to transmit light (FIG. 4). The pattern layer 3 may be formed by using an ordinary printing method such as an offset printing method, a gravure printing method, or a screen printing method.

The adhesive layer 4 adheres the above layers to the surface of a resin molded product obtained by cooling and solidifying a molten resin, which will be described later. As the adhesive layer 4, when the material of the molten resin is polyacrylic resin, it is preferable to use polyacrylic resin. Further, when the material of the molten resin is polyphenylene oxide / polystyrene resin, polycarbonate resin, styrene copolymer resin, polystyrene blend resin, polyacrylic resin, polystyrene resin, polyamide having affinity with these resins. A system resin or the like may be used.
As a method for forming the adhesive layer, there are coating such as a gravure coating method, a roll coating method and a comma coating method, and printing such as a gravure printing and a screen printing method. The dry film thickness of the adhesive layer 4 is generally 1 μm to 5 μm.

The insert film of the present invention has the following 3
There are types. First, a low reflection layer 2 made of a metal thin film was formed on one surface of a transparent substrate sheet 1, and a pattern layer 3 having a window part 31 and a transparent adhesive layer 4 were sequentially formed on the other surface. (Figs. 1 and 4). Second, a first low reflection layer 21 made of a metal thin film is formed on one surface of the transparent base sheet 1, a second low reflection layer 22 made of a metal thin film is formed on the other surface, and a pattern layer having a window portion. 3, transparent adhesive layer 4
Are sequentially formed (FIG. 2). Thirdly, the uneven surface 6 is formed between the base sheet 1 and the low reflection layer 2 in the first insert film (FIG. 3).
Alternatively, the uneven surface 6 is formed between the base sheet 1 and the first low reflection layer and / or between the base sheet 1 and the second low reflection layer in the second insert film.

In the method for producing a low reflection insert molded product having a cutout window according to the present invention, the low reflection insert film according to any one of the first to third embodiments is placed in the injection molding die 7 and the mold is closed. After that, a transparent molten resin 9 is injected into the mold on the adhesive layer 4 side of the low reflection insert film, and the molten resin 9 is solidified to bond the low reflection insert film to the transparent resin molded product 12. Yes (Fig. 5,
6 and 7).

The injection mold 7 used in this manufacturing method comprises a movable mold and a fixed mold. When arranging the low-reflective insert film in the injection molding die 7, the low-reflective insert film may be fed one by one, or may be arranged, or a necessary portion of the long low-reflective insert film may be intermittently placed. You may send in and arrange. When a long low-reflective insert film is used, it is advisable to use a feeder having a positioning mechanism so that the pattern layer of the low-reflective insert film and the injection molding die 7 are in register. Further, when the low reflection insert film is intermittently fed and arranged, if the low reflection insert film is fixed by the movable type and the fixed type after detecting the position of the low reflection insert film by the sensor, it is always the same. The low reflection insert film can be fixed in position,
It is convenient because the position of the design of the design layer 3 does not shift.
After the low reflection insert film is arranged, the low reflection insert film is brought into close contact with the inner surface of the movable concave portion (the concave portion may be referred to as “cavity”) by vacuum suction or heating. Then, the injection molding die 7 is closed,
The cavity 70 is formed (FIG. 3). The cavity 70 is filled with the molten resin 9 through the injection port 8 provided in the fixed mold to solidify the resin and form the resin molded product 12, and at the same time, the low reflection insert film is bonded to the surface.
After cooling the resin molded product 12, the injection molding die is opened and the resin molded product 12 is taken out. In this way, a low reflection insert molded product having a draft window can be obtained.

The low-reflection insert-molded product having the window part manufactured by using the first insert film is formed by the low-reflection layer made of a thin metal film having a small thickness in the window part. It has high transparency and antireflection effect. Further, since the low reflection layer is a hard metal thin film formed by vapor deposition or the like, it is strong against scratches, impacts, friction, etc., and the low reflection layer is not easily damaged.

The low reflection insert molded product having the cutout window portion manufactured by using the second insert film is the first
Similar to the insert film of No. 1, the transparency and antireflection effect of the draft window are high, and the low reflection layer is not easily damaged. Further, even if the first low-reflection layer 21 is damaged, the second low-reflection layer 22 is protected under the base sheet 1, so that the lack of the low-reflection effect due to the damage of the first low-reflection layer can be reduced. The low reflective layer supplements.

The low-reflection insert-molded article having a cutout window portion manufactured by using the third insert film is the first
Similar to the second insert film, the transparency and antireflection effect of the draft window are high, and the low reflection layer is less likely to be damaged. Further, even if the first low reflection layer 21 is damaged, the second low reflection layer 22 is protected under the base sheet 1,
The second low reflection layer compensates for the lack of the low reflection effect due to the damage of the first low reflection layer. In addition, since the metal thin film surface of the low reflection layer can be made uneven, the antireflection effect is further enhanced.

[0024]

Since the low reflection insert film of the present invention has the structure described in claims 1 to 3, since the low reflection layer is a metal thin film, it is extremely thin, and the transparency and antireflection effect of the draft window are improved. To do. Therefore, both the transparency and the antireflection effect of the punched window portion of the insert-molded product can be compatible with each other, and the transparency and the antireflection effect are sufficiently exerted.

The low reflection insert film of the present invention comprises
Since the structure according to claims 1 to 3 is adopted, the low reflection layer is a metal thin film and is therefore hard. Therefore, it is possible to manufacture an insert-molded product having a cut-out window portion in which the cut-out window portion of the insert-molded product is not easily scratched by scratching, impact, friction, or the like.

In the method of manufacturing a low reflection insert molded product having a cutout window according to the present invention, a low reflection insert film having a metal thin film formed to have a uniform film thickness is used. Even when a low-reflection layer is formed on a product and low-reflection processing is applied, the film thickness of the metal thin film does not differ depending on each part of the resin-molded product, and an antireflection effect is obtained uniformly over the entire required area of the resin-molded product. be able to. In addition, an anti-reflection effect and a sufficient transparency are exhibited, and an insert-molded product that is unlikely to be scratched in the draft window due to scratching, impact, friction or the like can be obtained.

According to the method for producing a low reflection insert molded article having a cut-out window portion of the present invention, the low reflection insert film is placed in the injection molding die and the mold is closed. By injecting a transparent molten resin into the mold and solidifying the molten resin, the insert film is adhered to the transparent resin molded product, which is only one step using the injection molding die and the insert film. Unlike conventional methods, it does not require labor, time and cost, and it has high production efficiency.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a low reflection insert film of the present invention.

FIG. 2 is a cross-sectional view showing an embodiment of another mode of the low reflection insert film of the present invention.

FIG. 3 is a cross-sectional view showing an embodiment of another mode of the low reflection insert film of the present invention.

FIG. 4 is a cross-sectional view showing an embodiment of another mode of the low reflection insert film of the present invention.

FIG. 5 is a cross-sectional view showing one of the steps of manufacturing a low reflection insert molded product having a cutout window portion of the present invention.

FIG. 6 is a cross-sectional view showing one of the steps of manufacturing a low reflection insert molded product having a draft window portion of the present invention.

FIG. 7 is a cross-sectional view showing a low reflection insert molded product having a draft window obtained by the manufacturing method of the present invention.

[Explanation of symbols]

1 Base sheet 2 Low reflective layer 21 First Low Reflection Layer 22 Second low reflection layer 3 picture layers 31 Window window 4 Adhesive layer 6 uneven surface 7 Injection mold 8 exit 9 Molten resin 12 Resin molded products

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Claims (2)

(57) [Claims] 1. A first low-reflection layer made of a metal thin film is formed on one surface of a transparent substrate sheet, and a second low-reflection layer made of a metal thin film is formed on the other surface, a pattern layer having a window portion, and a transparent layer. A low-reflection insert film, in which various adhesive layers are sequentially formed. 2. The low reflection insert film according to claim 1, wherein one surface or both surfaces of the transparent base sheet is an uneven surface.