JP3598220B2 - Method for manufacturing picture insert film and picture insert molding - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a paint insert film for painting a three-dimensional surface of an acrylonitrile butadiene styrene resin molded product suitable for an automobile interior or the like, and a method of manufacturing the paint insert molded product.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, there has been an automobile interior part or the like in which a picture insert film is integrally formed with an acrylonitrile butadiene styrene resin. In this way, the insert molding method of integrating the picture insert film onto the molded product simultaneously with the injection molding can form a pattern even in a molded product having a shape in which it is difficult to directly form a pattern by printing. It has the feature of being able to. The use of an acrylonitrile butadiene styrene resin as a molding resin has advantages in that it has better adhesion than polystyrene resin and polypropylene resin, is easier to mold, and is less expensive than polycarbonate resin.
[0003]
As a paint insert film for acrylonitrile butadiene styrene resin, a pattern layer is formed by printing a pattern layer on the surface of a biaxially stretched vinyl chloride film having a thickness of about 100 μm or more, and an overlay of about 200 μm is further formed thereon. An acrylic film is laminated as a weather-resistant film, and an acrylonitrile butadiene styrene film as an adhesive film is laminated on the back surface of a vinyl chloride film by a heat laminating method to form a three-layer structure having a total of about 500 μm (see FIG. 2). .
[0004]
The reason for such a configuration is that the technology for printing patterns on a vinyl chloride film has been established and the thickness of the film suitable for printing is about 100 μm, and that the overlay film is excellent in various properties such as weather resistance and transparency. A method of inserting a vacuum-molded film into a mold, in which the limit of the thickness that can be commercialized with a roll as an acrylic film is about 250 μm (that is, the thickness of the acrylic film is appropriately 50 to 250 μm). In, it is difficult to fix after insertion if there is no thickness of about 500 μm, and that wrinkles are likely to occur, because the total thickness of the vinyl chloride film and the acrylic film is up to about 300 to 350 μm at most. Acrylonitrile for adhesion purposes and to increase the total thickness of the film For example, laminating a butadiene styrene film.
[0005]
[Problems to be solved by the invention]
However, in the above-mentioned picture insert film, the vinyl chloride film is important as a support in printing and three-dimensional processing, but the vinyl chloride film contains a large amount of a plasticizer, and an insert molded product containing the plasticizer is contained. Cannot be reused as molding resin, and because the vinyl chloride film is located in the intermediate layer of the three-layer structure, it is difficult to separate and remove only the vinyl chloride film from the painted insert film. difficult. Acrylic film and acrylonitrile butadiene styrene film have similar properties.Acrylonitrile butadiene styrene film is a kind of acrylic resin in a broad sense and has high compatibility, so these films are mixed with acrylonitrile butadiene styrene resin as a molding resin. However, it can be used again as a molding resin. However, if a vinyl chloride film having a thickness of 100 μm is mixed, it is difficult to reuse the film as it is as a molding resin. Further, the vinyl chloride film generates a large amount of chlorine-based gas and the like at the time of waste incineration, and thus poses a problem of harm to environmental hygiene.
[0006]
Accordingly, it is an object of the present invention to provide a method for manufacturing a picture insert film and a picture insert molded product which can solve the above-mentioned drawbacks, is easy to recycle, and does not harm environmental hygiene.
[0007]
[Means for Solving the Problems]
The picture insert film of the present invention has the following configuration to achieve the above object.
[0008]
In other words, the picture insert film of the present invention is such that a pattern layer is provided on an acrylic film, an adhesive ink layer containing a vinyl resin or an acrylic resin as a main component is provided thereon, and an acrylonitrile butadiene styrene film is provided thereon. It was a laminated picture insert film in which the thickness of the acrylic film was 50 to 250 μm and the butadiene content was 20 to 50% by weight in the copolymerization ratio of the acrylonitrile butadiene styrene film.
[0009]
In the above invention, the adhesive ink layer mainly composed of a vinyl resin may be configured to be an adhesive ink layer composed of a polyvinyl chloride resin.
[0010]
In the above invention, the thickness of the picture insert film may be 350 to 1700 μm.
[0011]
Further, the method for producing a picture insert film according to the present invention is characterized in that the picture insert film according to claims 1 to 3 is inserted into a mold for injection molding, then three-dimensionally processed in the mold, and then clamped to finish the picture insert. An acrylonitrile butadiene styrene resin was injected onto the acrylonitrile butadiene styrene film side of the film, and the acrylonitrile butadiene styrene resin side of the picture insert film and the acrylonitrile butadiene styrene resin were bonded and integrated.
[0012]
Further, the method for producing a picture insert film according to the present invention is characterized in that a three-dimensionally processed picture insert film according to any one of claims 1 to 3 is inserted into a mold for injection molding, the mold is closed, and acrylonitrile butadiene styrene of the picture insert film is obtained. Acrylonitrile butadiene styrene resin was injected onto the film side surface, and the acrylonitrile butadiene styrene resin side surface of the picture insert film and the acrylonitrile butadiene styrene resin were bonded and integrated.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Embodiments of the present invention will be described in detail with reference to the drawings.
[0014]
FIG. 1 is a sectional view showing an embodiment of the picture insert film of the present invention. In the drawing, 1 is a picture insert film, 2 is an acrylic film, 3 is a design layer, 4 is an adhesive ink layer, and 5 is an acrylonitrile butadiene styrene film.
[0015]
In the insert film with picture 1 of the present invention, a pattern layer 3 is provided on an acrylic film 2, an adhesive ink layer 4 containing a vinyl resin or an acrylic resin as a main component is provided thereon, and acrylonitrile butadiene styrene is provided thereon. A paint insert film in which the film 5 is laminated, wherein the thickness of the acrylic film 2 is 50 to 250 μm, and the content ratio of butadiene in the copolymerization ratio of the acrylonitrile butadiene styrene film 5 is 20 to 50% by weight. (See FIG. 1).
[0016]
The acrylic film 2 has excellent transparency and is resistant to heat and light. In addition, it has a characteristic that it has excellent stain resistance without using a plasticizer, and has excellent moldability and can be deep drawn. As the acrylic film 2, it is preferable to use a thinner film than in the past. Specifically, the thickness of the acrylic film 2 is in the range of 50 to 250 μm, preferably 80 to 150 μm. If the thickness of the acrylic film 2 is less than 50 μm, printing of the design layer 3 becomes difficult. If it exceeds 250 μm, it will be difficult to commercialize it as a wound roll. Examples of the acrylic film 2 include polymethyl methacrylate resin, polyethyl methacrylate resin, polybutyl acrylate resin, ethylene-acryl copolymer resin, ethylene vinyl acetate-acryl copolymer resin, polyacrylonitrile resin, and styrene-acryl copolymer. It is preferable to use a film made of a polymer resin or the like.
[0017]
The design layer 3 is provided on the acrylic film 2. The design layer 3 is usually formed as a printing layer. As a material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, and a screen printing method may be used. In particular, an offset printing method or a gravure printing method is suitable for performing multicolor printing and gradation expression. In the case of a single color, a coating method such as a gravure coating method, a roll coating method, and a comma coating method may be employed. The printing layer may be provided entirely or partially depending on the design to be expressed. The thickness of the printing layer may be formed in the range of 0.5 to 50 μm. When the thickness is less than 0.5 μm, even if the pigment has a high concealing property, it becomes transparent when the picture insert film is stretched, and is affected by the color of the molding resin. When the thickness is more than 50 μm, the residual solvent is less likely to evaporate, corroding the acrylic film 2 and lowering mechanical strength such as tensile strength and bending strength.
[0018]
The design layer 3 may be formed of a metal thin film layer or a combination of a print layer and a metal thin film layer. The metal thin film layer is for expressing metallic luster as the design layer 3, and is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. Metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, and zinc, and alloys or compounds thereof are used according to the metallic luster color to be expressed. As an example of forming a partial metal thin film layer, after forming a solvent-soluble resin layer on a portion that does not require a metal thin film layer, a metal thin film is entirely formed thereon, and solvent cleaning is performed. There is a method of removing an unnecessary metal thin film together with the solvent-soluble resin layer. The solvent often used in this case is water or an aqueous solution. As another example, there is a method in which a metal thin film is formed on the entire surface, a resist layer is formed on a portion where the metal thin film is to be left, and the resist layer is removed by etching with an acid or an alkali. . When the metal thin film layer is provided, a front anchor layer or a rear anchor layer may be provided in order to improve adhesion between another layer and the metal thin film layer. As the material of the front anchor layer and the rear anchor layer, two-component cured urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, acrylic resin, epoxy It is preferable to use a resin such as a vinyl resin or a vinyl copolymer resin. Examples of the method for forming the front anchor layer and the rear anchor layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.
[0019]
Further, between the design layer 3 and the acrylonitrile butadiene styrene film 5, an adhesive ink layer 4 mainly composed of a vinyl resin or an acrylic resin is formed. The adhesive ink layer 4 is a layer for firmly bonding the acrylic film 2 on which the design layer 3 is formed and the acrylonitrile butadiene styrene film 5. The adhesive ink layer 4 is configured so that a vinyl resin or an acrylic resin is a main component. By using a vinyl resin or an acrylic resin as the adhesive ink layer 4, the pattern layer 3 printed on the acrylic film 2 and the acrylonitrile butadiene styrene film 5 can be easily bonded by means such as heat lamination or thermocompression bonding. it can. Further, since the vinyl-based resin or the acrylic-based resin is a thermoplastic resin which is softened by heating during three-dimensional processing and exhibits flexibility, it is also excellent in deep drawing characteristics. As a method for forming the adhesive ink layer 4, there are a gravure coating method, a roll coating method, a coating method such as a comma coating method, and a printing method such as a gravure printing method and a screen printing method. The dry thickness of the adhesive ink layer 4 is preferably 0.5 to 10 μm.
[0020]
The acrylonitrile butadiene styrene film 5 is for bonding the painting insert film 1 to an acrylonitrile butadiene styrene resin which is a molded product. As the acrylonitrile butadiene styrene film 5, a film having a butadiene content ratio higher than that of an existing product may be used to improve vacuum forming processability. In addition, since butadiene has rubber properties and is easily stretched, when the content of butadiene is increased, vacuum forming processability is improved, but various physical properties such as heat resistance are reduced. Therefore, in order to maintain physical properties and maintain vacuum formability, the butadiene content ratio is set to 20 to 50% by weight. Preferably it is 30 to 45% by weight. The conventional acrylic film, vinyl chloride film and acrylonitrile butadiene styrene film are laminated with a paint insert film.The acrylonitrile butadiene styrene film of the existing polymerization ratio is inferior in vacuum forming processability, so that the acrylonitrile butadiene styrene film is used for the entire paint insert film. Since the thickness ratio cannot be increased, it is difficult to reduce the thickness of the vinyl chloride film. In contrast, in the present invention, by setting the butadiene content of the acrylonitrile butadiene styrene film 5 within the above range, the acrylonitrile butadiene styrene film 5 having a larger thickness can be used. The thickness of the acrylonitrile butadiene styrene film 5 is preferably in the range of 100 to 1500 μm.
[0021]
The acrylonitrile butadiene styrene film 5 may be transparent or opaque. To make it opaque, for example, a coloring pigment such as red iron oxide, titanium oxide and carbon black, a metal powder such as aluminum flake, and a filler such as calcium carbonate and silica gel may be added.
[0022]
For laminating the acrylic film 2 and the acrylonitrile butadiene styrene film 5, it is preferable to use a thermal lamination method. As the conditions of the heat laminating method, it is preferable to apply pressure at a heat roller temperature of 130 to 200 ° C., preferably 140 to 170 ° C. for about 2 to 5 seconds.
[0023]
The total thickness of the picture insert film 1 is preferably 350 to 1700 μm. If the total thickness of the picture insert film 1 is less than 350 μm, the picture insert film 1 is easily deformed when it is removed from the mold after being three-dimensionally processed in a separate mold, and since there is no rigidity in the insert molding, the metal for injection molding is used. Difficult to insert into mold. On the other hand, when the total thickness exceeds 1700 μm, it takes a long time to perform vacuum forming because the formability of the picture insert film 1 is inferior, and it is difficult to punch into a desired shape after three-dimensional processing.
[0024]
In addition, the layer structure of the above-mentioned picture insert film 1 is an example of the picture insert film 1, and other layer structures may be used. For example, the adhesive ink layer 4 may also serve as the design layer 3 by mixing a coloring agent.
[0025]
In order to obtain a picture insert molded product using the picture insert film 1 having the above configuration, the following method may be used.
[0026]
The insert film with picture 1 is placed between a core mold having a molding resin injection port and a cavity mold having a concave portion for deep drawing by using an insert film feeder or the like. Fix around. Next, the paint insert film 1 is heated and softened by a heat source, and is vacuum-adsorbed from the cavity mold side to adhere to the surface of the cavity mold. The cavity mold and the core mold are clamped to form a closed space between the picture insert film 1 and the core mold. The molten molding resin is injected into this space. Acrylonitrile butadiene styrene resin is used as the molding resin. The acrylonitrile butadiene styrene resin referred to in the present application includes a heat-resistant ABS resin containing α-methylstyrene. The cavity mold and the core mold are opened, and unnecessary portions of the picture insert film are removed to obtain a picture insert molded product in which the picture insert film 1 and the molding resin are integrated.
[0027]
Moreover, a picture insert molded product can be obtained as follows. First, the painted insert film 1 is fixed to a preforming mold having a concave portion for deep drawing by means of a clamp or the like, and then the pictorial insert film 1 is heated and softened by a heat source and vacuum-sucked from the preforming mold side. To make close contact with the surface of the preforming mold. Next, the vacuum suction is released, and the picture insert film 1 is taken out of the preforming mold. Next, unnecessary portions of the picture insert film 1 are removed to obtain a three-dimensionally processed picture insert film 1 having a desired shape. Next, the three-dimensionally processed insert film with picture 1 is inserted into a cavity mold having a concave portion for deep drawing, and is fixed to the cavity mold. Next, the cavity mold and the core mold are clamped to form a closed space between the picture insert film 1 and the core mold. If the molten molding resin is injected into this space and the cavity mold and the core mold are opened, a picture insert molded product in which the picture insert film 1 and the molding resin are integrated can be obtained.
[0028]
【Example】
(Example 1) On an acrylic film having a thickness of 125 µm, a pattern layer was formed by a gravure printing method using an acrylic resin-based ink containing an aluminum pigment, and then an aluminum vapor-deposited layer having a thickness of 600 ° was formed as a metal thin film layer. Next, a vinyl chloride-vinyl acetate copolymer resin-based ink containing an aluminum pigment and a transparent yellow pigment is formed by a gravure printing method as an adhesive ink layer also serving as a post-anchor layer, and finally, a 300-μm-thick butadiene-containing 42% by weight acrylonitrile is used. A butadiene styrene film was laminated and thermally laminated at a temperature of 85 ° C., a pressing force of 8 kg / cm ² , and a speed of 5 m / min to obtain a picture insert film.
[0029]
The insert film with a picture was vacuum-formed from the acrylic film side by convex drawing, three-dimensionally processed, and then punched into a desired shape by a press die.
[0030]
Next, the three-dimensionally processed and punched picture insert film is inserted into a mold, and under the conditions of a molding resin temperature of 220 to 250 ° C. and a mold temperature of 40 to 60 ° C., a colorless and transparent acrylonitrile butadiene styrene copolymer resin is formed. Insert molding was performed as a molding resin to obtain an insert molded product with a picture, which is an automobile wheel cap.
[0031]
The insert molded product with picture obtained in this way was excellent in recyclability, and after use, was crushed as it was and could be used again as a molding resin. The amount of the vinyl chloride resin contained as the adhesive ink layer was 1 ppm or less as compared with the vinyl chloride film, the content of the plasticizer was small, and the recyclability was not affected.
[0032]
(Example 2) An acrylic resin ink containing a yellow pearl pigment was formed on an acrylic film having a thickness of 80 μm by using a yellow-orange wood grain conduit pattern and a transparent base color acrylic resin-based ink to form a pattern layer of a wood grain conduit pattern. Is used to form a pattern layer of a brilliant pigment layer, and then an acrylic resin-based ink containing a brown petal pattern pigment is used to form an adhesive ink layer also serving as a pattern layer of a wood grain base pattern. An acrylonitrile butadiene styrene film having a butadiene content of 38% by weight containing a pattern pigment and a thickness of 300 μm was laminated to obtain a picture insert film.
[0033]
Next, the picture insert film was three-dimensionally processed by vacuum forming and punched out in the same manner as in Example 1, inserted into a mold, clamped, injection molded using acrylonitrile butadiene styrene resin as a molding resin, A picture insert molded product as a console box was obtained.
[0034]
The insert molded product with picture obtained in this way is excellent in recyclability, and after use, can be directly crushed and reused as a molding resin. Further, there was no vinyl chloride resin contained as an adhesive ink layer, and there was no effect on recyclability.
[0035]
【The invention's effect】
Since the present invention has the above-described configuration, it has the following effects.
[0036]
The picture insert film of the present invention has a pattern layer provided on an acrylic film, an adhesive ink layer containing a vinyl resin or an acrylic resin as a main component is provided thereon, and an acrylonitrile butadiene styrene film is laminated thereon. A paint insert film having a thickness of 50 to 250 μm and a butadiene content of 20 to 50% by weight in the copolymerization ratio of an acrylonitrile butadiene styrene film. The acrylic film and the acrylonitrile butadiene styrene film are laminated only with the ink layer without using. Therefore, since the content of the vinyl chloride resin is extremely low or not contained at all, the amount of the plasticizer is extremely small, and the plasticizer is suitable for recycling. In addition, since little or no chlorine gas is generated, environmental health is not adversely affected.
[0037]
Further, since the conventional three-layer structure is changed to a two-layer structure, the number of vinyl chloride films can be reduced. Furthermore, since the configuration is simplified, the loss at the time of laminating is reduced, and the yield rate in manufacturing is improved when obtaining a picture insert film.
[0038]
In addition, the method for producing a picture insert molded product of the present invention comprises inserting the above picture insert film into an injection molding die and injecting acrylonitrile butadiene styrene resin to integrate the same. The amount of plasticizer is extremely low or not at all, so the amount of plasticizer is very small and suitable for recycling. Also, there is almost no or no generation of chlorine gas, so it is easy to produce painted inserts that do not adversely affect environmental hygiene. Obtainable.
[Brief description of the drawings]
FIG. 1 is a sectional view showing one embodiment of a picture insert film of the present invention.
FIG. 2 is a cross-sectional view showing one embodiment of a conventional picture insert film.
[Explanation of symbols]
1 Insert picture film 2 Acrylic film 3 Design layer 4 Adhesive ink layer 5 Acrylonitrile butadiene styrene film

Claims (5)

A design layer is provided on an acrylic film, an adhesive ink layer having a vinyl-based resin or an acrylic-based resin as a main component is provided thereon, and a acrylonitrile-butadiene styrene film is laminated on the insert film with a picture, An acrylic film having a thickness of 50 to 250 μm, and a butadiene content of 20 to 50% by weight in a copolymerization ratio of an acrylonitrile butadiene styrene film. The picture insert film according to claim 1, wherein the adhesive ink layer containing a vinyl resin as a main component is an adhesive ink layer made of a polyvinyl chloride resin. The picture insert film according to any one of claims 1 to 2, wherein the thickness of the picture insert film is 350 to 1700 µm. The acrylonitrile-butadiene styrene film on the surface of the acrylonitrile-butadiene styrene film side of the paint insert film after inserting the picture insert film according to any one of claims 1 to 3 into an injection molding mold, then performing three-dimensional processing in the mold, and closing the mold. A method for manufacturing a molded insert molded product, comprising injecting a resin, bonding an acrylonitrile butadiene styrene film-side surface of the coated insert film to an acrylonitrile butadiene styrene resin, and integrating them. The three-dimensionally processed insert paint film according to claims 1 to 3 is inserted into a mold for injection molding, the mold is clamped, and acrylonitrile butadiene styrene resin is injected onto the acrylonitrile butadiene styrene film side of the paint insert film, A method of manufacturing a molded insert molded product, comprising: bonding an acrylonitrile butadiene styrene film side surface of a painted insert film to an acrylonitrile butadiene styrene resin to be integrated.

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