JP3514726B2 - Glittering decorative sheet and method for producing glittering decorative product using the sheet - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to interior parts for automobiles such as console panels, center clusters, switch bases, side mat guards with painted patterns, bumpers,
The present invention relates to a glittering decorative sheet for decorating automobile exterior parts such as foil caps and malls, home electric appliances, mobile phones and the like, and a method for producing a glittering decorative product using the sheet.

[0002]

2. Description of the Related Art Conventionally, a glittering decorative sheet having a glittering layer formed on a thermoformable substrate sheet is preliminarily softened by heating outside or in an injection molding die, and then vacuum or A method for producing a glittering decorative product in which a molding resin is injected into a cavity after the mold is closed after being deformed by compressed air and the glittering decorative sheet and an injection-molded product are integrally bonded is implemented. In addition, "thermoforming" refers to softening the glittering decorative sheet by heating to deform it into an arbitrary shape.
For example, in order to deform the glittering decorative sheet by heating in advance and then deform it with a vacuum forming mold at another place, a planar heat source is arranged on both the front surface side and the back surface side of the glittering decorative sheet. After heating, (1) when the glittering decorative sheet itself moves from the planar heat source and moves to a place with a vacuum forming mold, or (2) when the planar heat source moves, the heat source There was a case where the vacuum forming mold came instead of replacing.

[0003]

However, in the case of (1), since the surface temperature is lowered during the movement of the glittering decorative sheet, when the vacuum forming mold is reached, the glittering decorative sheet is softened. In some cases, the degree has decreased and it was not possible to transform into a desired three-dimensional shape. In the case of (2), since the planar heat source moves to deprive the ambient temperature in the vicinity of the glittering decorative sheet, if the glittering decorative sheet is to be vacuum-formed, the glittering decorative sheet In some cases, the degree of softening is low, and it may not be possible to deform into a desired three-dimensional shape. As described above, when the degree of softening is once lowered and then reduced until vacuum forming, the glitter layer cannot follow the shrinkage of the base material sheet occurring at that time, and thus the glitter layer is wrinkled. Micro cracks were generated. Therefore, the microcracks reduce the glossiness of the glittering layer by half, and the glittering layer of the glittering decorative sheet is transparent, and the appearance is impaired, and the microcracks impair the moisture resistance to form a glittering metal layer. However, the physical properties are deteriorated such that they are easily corroded.

[0004]

[Means for Solving the Problems] In order to solve the above problems, the following is performed. As described in claim 1, the specular gloss Gs (6) after thermoforming of a glittering decorative sheet in which at least a glittering layer is formed on a thermoformable base sheet.
0 °) was a glittering decorative sheet that holds 43% or more before thermoforming in the measuring method defined in JIS-Z8741. As described in claim 2, the condition of thermoforming may be a glittering decorative sheet in which the glittering decorative sheet is softened by heating and then deformed by vacuum or pressure forming within 5 seconds. . The vapor deposition layer in which the glitter layer is formed by using any one of aluminum, chromium, indium, tin, nickel, gold, silver, copper, platinum, or an alloy thereof as described in claim 3. It may be a glittering decorative sheet. As described in claim 4, after softening the glittering decorative sheet according to any one of claims 1 to 3 by heating in advance, it is deformed by vacuum or compressed air, and then set in an injection molding die. , After closing the mold,
A method for producing a glittering decorative product was obtained by injecting a molding resin into the cavity and integrally bonding the glittering decorative sheet and the injection molded product. As set forth in claim 5, the glittering decorative sheet according to any one of claims 1 to 3 is set in an injection molding die, and after being softened by heating in the injection molding die, vacuum or A method for producing a glittering decorative product was obtained by deforming with compressed air to bring it into close contact with a mold, and after closing the mold, injecting a molding resin into the cavity to integrally bond the glittering decorative sheet and the injection molded product.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The glittering decorative sheet of the present invention comprises:
It is assumed that at least the glitter layer is formed on the thermoformable base sheet.

The material of the thermoformable base sheet is one that can be softened by heating and then deformed by vacuum or compressed air to have a desired three-dimensional shape. Specifically, acrylic resin, ABS is used. Resin, polypropylene resin,
Examples include polycarbonate resin, polybutylene terephthalate resin, polyvinyl chloride resin, and the like. The film thickness of the base material sheet is 100 to 750 × 10 ⁻³ mm, and particularly 200
˜500 × 10 ⁻³ mm is preferable. This is because wrinkles and tears are less likely to occur, and they easily follow fine grooves formed on the surface of a vacuum forming die or the like. The hardness of the base sheet is 2B to
2H is preferred. If it is less than 2B, it is too soft and easily deforms into a three-dimensional shape, and it easily dents or stretches, resulting in poor shape retention. If it is more than 2H, it is too hard to transform into a three-dimensional shape, and if forcedly deformed, it causes whitening. This is because it becomes a defective product. The elasticity of the base sheet is 1
It is preferably 0/1000 or less. When it is larger than 10/1000, the glittering decorative sheet is easily curled and cannot be set in the injection molding die. When the base sheet side, rather than the glitter layer side, is integrally bonded to the injection-molded article, the base sheet may or may not have an adhesive layer. It is considered that the adhesive layer may not be provided in some cases, because only the outermost surface layer of the base sheet itself is melted by the heat of the molding resin, which will be described later, to have adhesiveness, so that the bonding layer adheres to the molding resin. In order to facilitate the adhesion, it is effective to match the respective resin systems of the material of the base sheet and the material of the molding resin.

The glitter layer is preferably a vapor deposition layer made of any one of aluminum, chromium, indium, tin, nickel, gold, silver, copper and platinum, or an alloy thereof. The film thickness of the glitter layer is 100 to 800 × 1.
0 ^-3 mm range is preferred. The film thickness is 100 × 10 ⁻³
This is because if the thickness is smaller than mm, it is difficult to obtain the necessary metallic luster, and if the thickness is larger than 800 × 10 ⁻³ mm, it becomes too hard to be deformed into a three-dimensional shape. Furthermore, 300-60
The range of 0 × 10 ⁻³ mm is more preferable. Film thickness is 30
If it is smaller than 0 × 10 ⁻³ mm, a translucency may occur when it is deformed into a three-dimensional shape, and the film thickness is 800 × 10 ^−3.
If it is larger than mm, the adhesion with the adjacent layer is weakened due to the change with time and delamination occurs. Examples of the method for forming the glitter layer include a vacuum vapor deposition method, a sputtering method, and an electron beam method.

The glittering decorative sheet of the present invention further comprises:
Specular gloss Gs (60 °) after thermoforming is JIS-Z8
In the measuring method specified in 741, 43 before thermoforming
% Or more. Specular gloss Gs (60
) Means that the light from the standard light source is applied to the sample surface at a specified angle and the specular reflection component is measured by the light receiver, and the incident angle and the reflection angle are 60 plus / minus 0.
It is set to be 1 °. When the specular gloss is measured by this JIS code measuring method, the occurrence of the microcracks can be easily confirmed. The condition that the specular gloss Gs (60 °) is maintained at 43% or more is that a decorative sheet heated at a temperature capable of being deformed into a desired three-dimensional shape by thermoforming occurs in the glitter layer. Minimize the occurrence of micro cracks, and
This is because it is a numerical value that can maintain the glossiness in design.
As an example of the thermoforming conditions, the heating temperature is 400 to 75.
There is an example in which a glittering decorative sheet is heated and softened by using a heat source set to 0 ° C. and then deformed by vacuum or pressure molding within 5 seconds. The heating temperature is set to 400 to 750 ° C. in order to prevent insufficient heating of the glitter layer due to heat radiation, particularly when heating from the glitter layer side. Also, vacuum or pressure forming within 5 seconds to deform is that if the time from heating and softening the glittering decorative sheet to vacuum or pressure forming is longer than 5 seconds, the glittering decorative sheet is decorated. This is because the contraction of the sheet starts and microcracks occur in the glitter layer. The heating time varies depending on the material of the base sheet of the glittering decorative sheet. For example, as the thickness of the base material sheet increases, the heating time also increases. The softening of the glittering decorative sheet by heating in advance can be performed by bringing a hot plate close thereto, blowing hot air, or irradiating far infrared rays. Further, in order to deform the glittering decorative sheet, it is possible to use a method of deforming by utilizing a pressure difference of air by vacuum or compressed air.

An adhesive layer 2 may be formed between the base sheet 1 and the glitter layer 3. The adhesive layer 2 is intended to improve the adhesion strength between the base sheet 1 and the glitter layer 3. In particular, since it is required to have resistance to vibrations, shocks, and adhesion of moisture and oil for automobile applications, it is preferable to form an adhesive layer for maintaining resistance. As a material for the adhesive layer, vinyl chloride vinyl acetate copolymer resin or the like may be used. When the material of the base sheet is polypropylene resin, urethane resin or the like may be used as the material of the adhesive layer. As a method for forming the adhesive layer, a well-known printing method such as a gravure printing method, or a well-known coating method such as a gravure coating method, a silk coating method, a lip coating method, a reverse coating method, or the like may be used.

A surface protective layer may be further formed on the glitter layer. The surface protective layer is intended to improve the rust resistance, crack resistance, weather resistance and kill resistance of the glitter layer. In particular, for automotive applications, resistance to vibration, impact, and adhesion of water and oil is required, and it is preferable to form a surface protective layer for maintaining resistance. Materials for forming the surface protective layer by a printing method or a coating method include acrylic resin and acrylic urethane resin. An electron beam curable or ultraviolet curable material in which a photopolymerization initiator is contained in these resins may be used. As a printing method, there is a known printing method such as a gravure printing method. As the coating method, there are known coating methods such as a gravure coating method, a silk coating method, a lip coating method and a reverse coating method. Materials for forming the surface protective layer as a thermoformable sheet include acrylic resin, polycarbonate resin, and fluorine-containing acrylic resin. A sheet obtained by laminating a sheet made of a polycarbonate resin and a sheet made of a polybutylene terephthalate resin may be used as the surface protective layer.

When the surface protective layer is formed as a constituent layer of the transfer layer, a release layer for facilitating the separation between the transfer layer and the base sheet can be used as the surface protective layer. In this case, the material includes acrylic resin, cellulose resin and urethane resin. Alternatively, lacquer (acrylic resin, acrylic resin, polyol resin, acrylic resin, acrylic urethane resin) may be used.

As a method for forming the glitter layer, the adhesive layer, and the surface protective layer on the thermoformable base sheet, a stretched base sheet prepared separately from the thermoformable base sheet is used. A glitter layer, an adhesive layer, or a surface protective layer is once formed by printing or the like to form a transfer sheet, and then the glitter layer, the adhesive layer, or the surface protective layer is formed on the thermoformable base sheet. There are a method of transferring and a method of directly printing a glitter layer, an adhesive layer, and a surface protective layer on a thermoformable substrate sheet.

Next, a method for manufacturing the glittering decorative article of the present invention will be described. One method is to soften the glittering decorative sheet by heating in advance, deform it with vacuum or compressed air, and then set it in the injection molding die.After closing the die, inject the molding resin into the cavity to make it bright. The property-decorating sheet and the injection-molded product are integrally bonded. In order to soften the glittering decorative sheet by heating before setting it in the injection molding die, as shown in FIGS. 3 to 6, first, in a state in which the vacuum molding die 11 is made to stand by below, The upper heat source 8 and the lower heat source 9 are moved in parallel by the slide device 13 to cover the upper and lower surfaces of the glittering decorative sheet 5 whose both ends or the periphery are fixed by the clamp 10. Heating is 400-75
The hot plate heated to 0 ° C. is heated from the surface of the glittering decorative sheet 5 at a distance of about 10 cm for about 6 to 10 seconds (see FIG. 3). After being softened by heating, the upper heat source 8 and the lower heat source 9 are moved in parallel by the slide device 13 to move the upper heat source 8 and the lower heat source 9 to the glittering decorative sheet 5.
Return to the original standby position from above and below (see FIG. 4). Immediately, the vacuum forming die 11 that has been waiting downward is moved upward to press the convex portion of the vacuum forming die 11 against the glittering decorative sheet and suck it through the vacuum suction holes 12 to form the vacuum forming die 1
The protrusion 1 is deformed along the outer surface (see FIGS. 4 and 5). If necessary, the glittering decorative sheet 5 may be compressed from above the vacuum forming mold 11. In any of the above states, it is preferable that the glittering decorative sheet 5 be kept stationary. This is for avoiding as much as possible that the degree of softening is reduced or fluttering due to movement of the glittering decorative sheet itself is received. In order to set the deformed glittering decorative sheet in the injection molding die 14, it may be fitted into the concave portion or the convex portion of the injection molding die (see FIG. 6).

As another method, the glittering decorative sheet is set in an injection-molding die, softened by heating in the injection-molding die, and then deformed by vacuum or compressed air to be brought into close contact with the die. After the mold is closed, a molding resin is injected into the cavity to integrally bond the glittering decorative sheet and the injection molded product. In this case, it is not necessary to process the injection molding die in order to attach the vacuum device or the pneumatic device, or to install a device such that the heating device goes in and out between the molds.
The injection molding device is simple and the molding time can be shortened. When heating in the injection mold, heating is 400 ~
Introducing a heat source (for example, a hot plate) heated to 750 ° C into the injection molding die to make a glittering decorative sheet pressed by a clamp around the concave portion of the female die of the injection molding die. Bring them closer. Next, about 1 from the surface of the glittering decorative sheet
Heat for about 6-10 seconds with 0 cm spacing. The heating may be performed only from the base material sheet side of the glittering decorative sheet, or from only the decorating layer surface side, or may be performed from both the base material sheet side and the decorating layer side of the glittering decorative sheet. . After being softened by heating, the heat source is moved from the inside of the injection molding die to the outside and immediately deformed by vacuum suction and, if necessary, compressed air. The vacuum suction may be performed by sucking through the vacuum suction holes 12 formed on the surface of the female concave portion and attracting the glittering decorative sheet 5 softened by heating to follow the inner surface of the female concave portion. The compressed air may be produced by injecting hot air from a compressed air opening formed on the surface of the convex portion of the male mold, and pressing the glittering decorative sheet softened by heating against the inner surface of the concave portion of the female mold to bring it into close contact (not shown). .

Molding resin 6 injected into the cavity after the mold is closed
Examples thereof include heat-resistant ABS resin, polycarbonate resin, polypropylene resin, alloy of ABS resin and polycarbonate resin, and the like. A glittering decorative product in which the glittering decorative sheet and the injection-molded product are integrally bonded is obtained.

[0016]

Example 1 A glitter decorative sheet was obtained in which a glitter layer composed of a chromium vapor deposition layer was formed on a thermoformable base sheet made of ABS resin having a thickness of 0.35 mm by thermal lamination. The 60 ° specular gloss Gs (60 °) determined by JIS-Z8741 of this glittering decorative sheet was 381 or more. The glittering decorative sheet was evaluated using a simple vacuum forming machine Formech 450 having a heat source under the conditions shown in the table below. From this evaluation result, in the glittering decorative sheet using the thermoformable base material sheet made of ABS resin having the thickness of 0.35 mm, vacuum suction is performed within 5 seconds after the heat source is moved, and the specular gloss after thermoforming is obtained. It can be seen that when the degree Gs is 43% or more before the thermoforming, the formed glitter decorative sheet with high gloss can be obtained without generating microcracks. In addition, "drawability" in the table means shape conformability with respect to the mold surface when the glittering decorative sheet is softened and vacuum sucked.

[0017]

[Table 1]

[0018]

The glittering decorative sheet of the present invention has a specular gloss Gs (60) after thermoforming of a glittering decorative sheet in which at least a glittering layer is formed on a thermoformable base sheet.
In the measuring method defined in JIS-Z8741, the temperature of (°) was kept at 43% or more before thermoforming. Further, the method for producing a glittering decorative article of the present invention, before or after setting the glittering decorative sheet in the injection molding die, deformed by vacuum or compressed air, after closing the mold,
A molding resin was injected into the cavity to integrally bond the glittering decorative sheet and the injection molded product.

Therefore, in the glitter decorative sheet of the present invention, even if the degree of softening is once raised and then lowered before vacuum forming, the glitter layer is caused by the shrinkage of the base sheet at that time. Wrinkle-like microcracks do not occur. Therefore, the glossiness of the glittering layer is reduced by half due to microcracks and the glittering layer of the glittering decorative sheet is transparent, and the appearance is impaired. It is also possible to suppress deterioration of physical properties such that the layer is easily corroded.

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of a glittering decorative sheet of the present invention.

FIG. 2 is a cross-sectional view showing an example of a glittering decorative product obtained by the manufacturing method of the present invention.

FIG. 3 is a cross-sectional view showing a state where the glittering decorative sheet of the present invention is being heated.

FIG. 4 is a cross-sectional view showing a state after heating the glittering decorative sheet of the present invention.

FIG. 5 is a cross-sectional view showing a state where the glittering decorative sheet of the present invention is placed along a vacuum forming die.

FIG. 6 is a cross-sectional view showing one step of a method for producing a glittering decorative article of the present invention.

[Explanation of symbols]

1 Base sheet 2 Adhesive layer 3 glitter layer 4 Surface protection layer 5 glittering decorative sheet 6 Molding resin 8 Upper heat source 9 Lower heat source 10 clamps 11 Vacuum mold 12 Vacuum suction hole 13 Sliding device 14 Injection Mold

Claims (5)

(57) [Claims] Claims: 1. A glittering decorative sheet having at least a glittering layer formed on a thermoformable base sheet is heated to a temperature not lower than the softening temperature of the glittering decorative sheet, and then vacuum or within 5 seconds. A method for thermoforming a glittering decorative sheet, which comprises pressure forming. 2. The glitter layer is a vapor-deposited layer formed by using any one of aluminum, chromium, indium, tin, nickel, gold, silver, copper, platinum, or an alloy thereof. 1. A method for thermoforming a glittering decorative sheet according to 1. 3. Specular gloss Gs (60 °) after thermoforming by the thermoforming method according to claim 1 or 2.
However, in the measuring method defined in JIS-Z8741, a glittering decorative sheet, characterized in that it retains 43% or more before thermoforming. 4. The glittering decorative sheet according to claim 3 is softened by heating in advance, deformed by vacuum or compressed air, and then set in an injection molding die. After the die is closed, a molding resin is placed in the cavity. Is injected, and the glittering decorative sheet and the injection-molded article are integrally bonded, and a method for producing the glittering decorative article. 5. The glitter decorative sheet according to claim 3 is set in an injection molding die, softened by heating in the injection molding die, and then deformed by vacuum or air to obtain a die. After closely contacting and closing the mold, inject molding resin into the cavity,
A method for producing a glittering decorative article, which comprises integrally bonding the glittering decorative sheet and an injection molded product.