JP3896243B2 - Deep drawing decoration film for simultaneous molding - Google Patents

Description

【００１６】
【化２】

【００１７】
また、ポリカーボネート樹脂とともに基材フィルム２を構成する上記ポリカーボネート樹脂以外の樹脂としては、例えばＡＡＳ（アクリロニトリル・アクリルゴム・スチレン）、ＥＥＡ（エチレン・アクリル酸エステル）、ＡＢＳ（アクリロニトリルブタジエンスチレン）、ＡＣＳ（アクリロニトリル・塩素化ポリエチレン・スチレン）や、ＰＥＮ（ポリエチレンナフタレート）、ＰＢＴ（ポリブチレンテレフタレート）、ＰＥＴ（ポリエチレンテレフタレート）等のポリエステル樹脂、およびこれらを変性したものを使用することができるが、ポリカーボネート樹脂以外の樹脂であれば特に限定されない。なお、印刷工程で使用される有機溶剤にほとんど侵されない程度および成形品の表面に一体化接着されてから洗剤やアルコール等を含んだもので表面を拭いても全くクラックが入らない程度まで耐溶剤性及び耐薬品性を大きく向上させるには、ポリカーボネート樹脂とポリカーボネート樹脂以外の樹脂との重量組成比が８５：１５であるか、該重量組成比よりもポリカーボネート樹脂以外の樹脂の比率が高くなるように混合すればよい。
【００１８】
また、基材フィルム２は、そのＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が８５〜１２０℃であるものを用いる。このような特性の基材フィルム２を用いることにより、印刷時の寸法安定性と予備成形時の熱成形性とを兼ね備えた加飾フィルムを得ることができる。
【００１９】
加飾フィルムの印刷時の寸法安定性を考えると、基材フィルム２が、その上に図柄層３などの印刷層を設ける工程において６０〜８０℃で乾燥加熱され且つ長尺の基材フィルム２について巻き取り装置付き機械で印刷するとき（ロールツーロールという）には巻き取り等のテンションをかけられた状態で寸法変化を起こさない材料、又は寸法変化を少量起こしても良いがその変化が一定量に管理される材料でなければならない。本発明者が各種の熱変形温度の基材フィルム２について印刷乾燥を試みた結果、本発明のように基材フィルム２としてＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が８５〜１２０℃であるものを用いる。このような特性のによる熱変形温度（荷重たわみ温度）が８５℃以上のものを用いれば、印刷工程時の寸法安定寸性を得ることができることがわかった。なお、ここで寸法変化が起こるとは、熱膨張以外の伸縮が元の長さに対し１％以上起こることをいう。
【００２０】
一方、加飾用フィルムの予備成形時の熱成形性を考えると、ヒーターと外気温度との差が大きくならないように、基材フィルム２は、予備成形時に加える熱が低くて済むような材料でなければならない。本発明者が各種の熱変形温度の基材フィルム２を有する加飾用フィルムについて予備成形を試みた結果、本発明のように基材フィルム２としてＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が１２０℃以下のものを用いれば、予備成形時にヒーターと外気温度との差が充分に小さくでき、その結果、加飾用フィルムの伸びやすさが部分によって異なったり、個々の予備成形で伸びやすさのばらつきがでたりすることがなく、また部分的に加熱しすぎた状態での真空引きにより穴があくこともなく、予備成形時の熱成形性を得ることができることがわかった。
【００２１】
上記ＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が８５〜１２０℃となるような基材フィルム２とは、上記基材フィルム２に用いるポリカーボネート樹脂以外の樹脂としてアクリロニトリルブタジエンスチレン、ポリブチレンテレフタレート、ポリエチレンテレフタレートおよびこれらの変性樹脂のうち少なくとも１つを用い、ポリカーボネート樹脂とポリカーボネート樹脂以外の樹脂との重量組成比が８２：１９〜３８：６２であるものが適していることがわかった。
【００２２】
ポリカーボネート樹脂の割合が上記重量組成比８２：１９より多くなると、基材フィルムのＡＳＴＭ−Ｄ６４８法による荷重たわみ温度が１２０℃より高くなり、ポリカーボネート樹脂単体のフィルム（荷重たわみ温度１２５〜１５０℃）に近い耐熱性になる。すなわち、予備成形時の熱成形性が充分に得られない。一方、ポリカーボネート樹脂の割合が上記重量組成比３８：６２より少なくなると、基材フィルム２のＡＳＴＭ−Ｄ６４８法による荷重たわみ温度が８５℃より低くなり、印刷工程での乾燥熱（主に６０〜８５℃）に対する基材フィルム２の寸法安定性が十分に得られない。
【００２３】
また、上記基材フィルムの厚みは０．０５〜１ｍｍの範囲にするのが好ましい。厚みが０．０５ｍｍ未満だと、成形同時加飾の際の樹脂圧力で破れやすくなるという問題や、射出成形用金型外で予備成形して金型内に供給する際にフィルムが薄すぎて取り扱いにくくなるという問題があるからである。また、厚みが１ｍｍを超えると、印刷機が対応できないものが多く、印刷が困難になるという問題があるからである。
【００２４】
また、本発明の基材フィルムには無延伸フィルムを用いるのが好ましい。無延伸フィルムとは、未延伸フィルムともいい、成膜の際に延伸工程を故意にかけないものをいう。なお、基材フィルムを長尺で製造する場合、最後に巻き取り工程があるために基材フィルムを巻き取る方向には延伸がいくらかかかるが、その際にはできるだけテンション値を小さくして巻くようにする。一般に、延伸されたフィルムは延伸によってフィルム内での結晶化が進み、機械的強度が強すぎる。そのため、延伸されたフィルムを基材フィルムに用いた加飾フィルムは予備成形がしにくく、とくに深絞り成形にはあまり向いていないという問題がある。これに対し無延伸フィルムでは、延伸がされないため結晶化が進まず、機械的強度が強すぎない。したがって、無延伸フィルムを基材フィルムに用いた加飾フィルムは予備成形がしやすく、深絞り成形も容易である。無延伸フィルムの製造には、Ｔダイ押出し法、カレンダー法、キャスティング法等が使用できる。
【００２５】
なお、上記ＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）はＪＩＳ Ｋ−６８７１（１８．６ｋｇ）と同様の測定法であるため、本発明の加飾用フィルム１は、基材フィルム２のＪＩＳ Ｋ−６８７１（１８．６ｋｇ）による熱変形温度（荷重たわみ温度）を８５〜１２０℃としてもよい。
【００２６】
本発明に用いる加飾用フィルム１としては、転写材やインサート材を用いることができる。
【００２７】
インサート材は、基材フィルム２上に図柄層３などが形成されたものである。
【００２８】
図柄層３は、基材フィルム２の表面または裏面のどちらか片面、あるいは両面にパターンの印刷をして形成するとよい。図柄層３は、通常、印刷層として形成する。印刷層の材質としては、ウレタン系樹脂、ビニル系樹脂、ポリアミド系樹脂、ポリエステル系樹脂、アクリル系樹脂、ポリウレタン系樹脂、ポリビニルアセタール系樹脂、ポリエステルウレタン系樹脂、セルロースエステル系樹脂、アルキド樹脂、熱可塑性エラストマーなどの樹脂、好ましくは柔軟な皮膜を作ることができる樹脂をバインダーとし、適切な色の顔料または染料を着色剤として含有する着色インキを用いるとよい。印刷層の形成方法としては、オフセット印刷法、グラビア印刷法、スクリーン印刷法などの通常の印刷法などを用いるとよい。特に、多色刷りや階調表現を行うには、オフセット印刷法やグラビア印刷法が適している。印刷の主な流れは、例えばグラビア輪転の場合を例にとると、印刷されるシートを巻出部５より連続的に送り出した後、先ず最初の印刷ユニットにおいて、表面にインキパン６からインキが供給された回転する版胴７とこの版胴７に対して圧力を加える圧胴８との間にシートを通すことによってシート上にインキを転移して印刷層を形成し、続けてシートを蒸気ドラム、熱風、冷風などの乾燥部９に通すことによって印刷層を乾燥した後、シートを次の印刷ユニットに送り、前印刷ユニットと同様にして別の印刷層をシート上に形成するといった工程を何度かくり返し、全ての印刷層を形成した後にシートを巻取部１０に巻き取るという工程を経るというものである。なお、見当合わせのためには、多数のガイドロール１１にてテンションを微細に調節すればよい。どのような印刷方法にしろ、インキ中の溶剤、シンナー分を乾燥させるため、印刷層は自然乾燥ではなく、加熱によって行なわれる。本発明の加飾用フィルム１は、基材フィルムのＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が８５〜１２０℃のものを用いるので、印刷時の乾燥熱によっても、基材フィルム上に印刷された図柄パターンにひずみが発生したり、また多色印刷工程での各色パターンどうしの見当合わせが難しかったりすることがない。
【００２９】
また、図柄層３は、印刷層だけでもよし、また印刷層と金属薄膜層との組み合わせからなるものでもよい。金属薄膜層は、図柄層３として金属光沢を表現するためのものであり、真空蒸着法、スパッターリング法、イオンプレーティング法、鍍金法などで形成する。表現したい金属光沢色に応じて、アルミニウム、ニッケル、金、白金、クロム、鉄、銅、スズ、インジウム、銀、チタニウム、鉛、亜鉛などの金属、これらの合金または化合物を使用する。部分的な金属薄膜層を形成する場合の一例としては、金属薄膜層を必要としない部分に溶剤可溶性樹脂層を形成した後、その上に全面的に金属薄膜を形成し、溶剤洗浄を行って溶剤可溶性樹脂層と共に不要な金属薄膜を除去する方法がある。この場合によく用いる溶剤は、水または水溶液である。また、別の一例としては、全面的に金属薄膜を形成し、次に金属薄膜を残しておきたい部分にレジスト層を形成し、酸またはアルカリでエッチングを行い、レジスト層を除去する方法がある。
【００３０】
また、接着層を形成してもよい。接着層は、成形樹脂１７にインサート材を接着するものであり、必要に応じて加飾用フィルム１の図柄層３側または基材フィルム２側に形成する。接着層としては、成形樹脂１７の素材に適した感熱性あるいは感圧性の樹脂を適宜使用する。たとえば、成形樹脂１７の材質がアクリル系樹脂の場合はアクリル系樹脂を用いるとよい。また、成形樹脂１７の材質がポリフェニレンオキシド・ポリスチレン系樹脂、ポリカーボネート系樹脂、スチレン共重合体系樹脂、ポリスチレン系ブレンド樹脂の場合は、これらの樹脂と親和性のあるアクリル系樹脂、ポリスチレン系樹脂、ポリアミド系樹脂などを使用すればよい。さらに、成形樹脂１７の材質がポリプロピレン樹脂の場合は、塩素化ポリオレフィン樹脂、塩素化エチレン−酢酸ビニル共重合体樹脂、環化ゴム、クマロンインデン樹脂が使用可能である。接着層の形成方法としては、グラビアコート法、ロールコート法、コンマコート法などのコート法、グラビア印刷法、スクリーン印刷法などの印刷法がある。
【００３１】
また、上記印刷工程を経た基材フィルムに、バッキングシート４を積層してもよい（図３参照）。バッキングシート４は、加飾用フィルム１に腰の強さを付与して射出成形の型外で加飾用フィルムを予備成形をする場合や射出成形型内に加飾用フィルムを供給する場合の取り扱いを容易にし、また射出成形樹脂と融着させるためのものである。ただし、バッキングシート４はＡＳＴＭ−Ｄ６４８法（１８２０ＭＰａ）による熱変形温度（荷重たわみ温度）が１２０℃以下のフィルムを使用する。バッキングシート４の熱変形温度が１２０℃を超えると、加飾用フィルムを予備成形するために高温が必要となり、加飾用フィルムの伸びやすさが部分によって異なったり、個々の予備成形で伸びやすさのばらつきがでたりするからである。なお、本発明のバッキングシート４は印刷工程を経ないので、変形温度（荷重たわみ温度）が８５℃以上である必要はない。上記ＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が１２０℃以下であるバッキングシート４としては、たとえば、ポリプロピレン（熱変形温度４９〜６０℃）樹脂などを使用すればよい。
【００３２】
次に、加飾用フィルム１を転写材として用いる場合について説明する。転写材は、基材フィルム２上に、剥離層、図柄層３、接着層などからなる転写層が設けられたものである。
【００３３】
基材フィルム２としては、インサート材の場合と同様のものを用いることができる。基材フィルム２からの転写層の剥離性を改善するためには、基材フィルム２上に転写層を設ける前に、離型層を全面的に形成してもよい。離型層は、転写後に基材フィルム２を剥離した際に、基材フィルム２とともに転写層から離型する。離型層の材質としては、メラミン樹脂系離型剤、シリコーン樹脂系離型剤、フッ素樹脂系離型剤、セルロース誘導体系離型剤、尿素樹脂系離型剤、ポリオレフィン樹脂系離型剤、パラフィン系離型剤およびこれらの複合型離型剤などを用いることができる。離型層の形成方法としては、ロールコート法、スプレーコート法などのコート法、グラビア印刷法、スクリーン印刷法などの印刷法がある。
【００３４】
剥離層は、基材フィルム２または離型層上に全面的または部分的に形成する。剥離層は、転写後に基材フィルム２を剥離した際に、基材フィルム２または離型層から剥離して被転写物の最外面となる層である。剥離層の材質としては、アクリル系樹脂、ポリエステル系樹脂、ポリ塩化ビニル系樹脂、セルロース系樹脂、ゴム系樹脂、ポリウレタン系樹脂、ポリ酢酸ビニル系樹脂などのほか、塩化ビニル−酢酸ビニル共重合体系樹脂、エチレン−酢酸ビニル共重合体系樹脂などのコポリマーを用いるとよい。剥離層に硬度が必要な場合には、紫外線硬化性樹脂などの光硬化性樹脂、電子線硬化性樹脂などの放射線硬化性樹脂、熱硬化性樹脂などを選定して用いるとよい。剥離層は、着色したものでも、未着色のものでもよい。剥離層の形成方法としては、グラビアコート法、ロールコート法、コンマコート法などのコート法、グラビア印刷法、スクリーン印刷法などの印刷法がある。
【００３５】
図柄層３は、インサート材の場合と同様にして設けるとよい。
【００３６】
接着層は、成形樹脂１７表面に上記の各層を接着するものである。接着層は、接着させたい部分に形成する。すなわち、接着させたい部分が全面的なら、図柄層３上に接着層を全面的に形成する。また、接着させたい部分が部分的なら、図柄層３上に接着層を部分的に形成する。接着層は、インサート材の場合と同様にして設けるとよい。
【００３７】
次に、成形同時加飾成形品の製造方法を説明する。
【００３８】
まず、加飾用フィルム１を射出成形用の金型である可動型１２の表面にクランプ部材１５によりセットする（図４参照）。
【００３９】
可動型１２へのセットの仕方の具体例としては、ロール軸に長尺の加飾用フィルム１を一旦巻き取ってロール状巻物とし、このロール状巻物を射出成形用の可動型１２の上部に可動型１２と一体的に移動可能に載置し、ロール状巻物から加飾用フィルム１を巻き出しながら、退避した可動型１２と固定型１３との間を通過させ、射出成形用の可動型１２の下部に可動型１２と一体的に移動可能に設置したフィルム巻き取り手段のロール軸により加飾用フィルム１を巻き取るようにすればよい。別の例としては、枚葉の加飾用フィルム１を用いて、ロボットや人手により可動型１２の表面にセットしてもよい。加飾用フィルム１の可動型１２の表面へのセットに際しては、加飾用フィルム１を可動型１２の表面に配置した後、可動型１２の表面に対する加飾用フィルム１の位置を位置決めセンサーなどにより決定し、加飾用フィルム１を射出成形用の可動型１２の表面にクランプ部材１５によって押さえ付けるとよい。
【００４０】
次いで、加飾用フィルム１を射出成形用の可動型１２の表面にセットした後に、射出成形用の可動型１２に形成された真空吸引孔１９を利用して、加飾用フィルム１を可動型１２のキャビティ形成面１４に沿わせるように真空吸引することにより、射出成形用の可動型１２の凹部すなわちキャビティ２０のキャビティ形成面１４に沿うように予備成形する（図５参照）。具体例としては、可動型１２と固定型１３との間に挿入した加熱板２１などのヒーターで、可動型１２の表面にセットした加飾用フィルム１を加熱して軟化させ、射出成形用の可動型１２の凹部と加飾用フィルム１との間の空間を密閉して真空吸引孔１９から排気して真空吸引し、射出成形用の可動型１２の凹部内面（キャビティ形成面１４）に加飾用フィルム１を密着させる方法がある。予備成形を行なう際、あるいはクランプ部材１５で加飾用フィルム１を押さえ付けて固定する際に、加飾用フィルム１の不要部分の打抜き加工をしてもよい。本発明の加飾用フィルム１は、基材フィルムのＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が８５〜１２０℃のものを用いるので、上記予備成形時にヒーターと外気温度との差を充分に小さくでき、その結果、加飾用フィルムの伸びやすさが部分によって異なったり、個々の予備成形で伸びやすさのばらつきがでたりすることがない。また、部分的に加熱しすぎて真空引きにより穴があくこともない。
【００４１】
上記方法に代えて、加飾用フィルム１を射出成形用の可動型１２の表面にセットする前に、射出成形用の可動型１２と固定型１３とは別の立体加工成形用型を用いて加飾用フィルム１をあらかじめ所望の立体形状に予備成形し、また所望の形状に打抜き加工したのち、射出成形用の可動型１２の凹部内に、予備成形された加飾用フィルム１をはめ込むようにしてもよい（図６参照）。所望の立体形状としては、射出成形用の可動型１２または固定型１３のキャビティ形成面１４に合致する形状などがある。立体形状に加工する方法としては、真空成形法や圧空成形法、熱せられたゴムを押しつける押圧成形法などがある。所望の形状に打抜き加工する方法としては、トムソン打抜き法、金型によるプレス法などがある。打抜き形状としては、所定形状の外周に沿った線や所定形状の孔などがある。なお、立体形状に加工する際に同時に打抜き加工をしてもよい。
【００４２】
次に、固定型１３に対して可動型１２を型閉めして溶融状態の成形樹脂１７を固定型１３のゲート部１６からキャビティ２０内に射出し、成形樹脂１７を固化させてキャビティ２０内で樹脂成形品１８を形成すると同時にその表面に加飾用フィルム１を一体化接着させる（図７参照）。
【００４３】
その後、樹脂成形品１８を可動型１２から取り出したのち、樹脂成形品１８に接着した加飾用フィルム１のうち不要な部分を除去する（図８参照）。なお、上記したようにあらかじめ所望の形状に打ち抜き加工していた場合には、加飾用フィルム１の不要な部分を除去する作業は不要である。
【００４４】
射出成形用の金型としての可動型１２と固定型１３は、上記した実施形態に特に限定されることはなく、成形樹脂１７を射出するゲート部１６を有する固定型１３と可動型１２から構成され、固定型１３と可動型１２とが型閉めされることによって、固定型１３および可動型１２のキャビティ形成面１４によって囲まれた単数あるいは複数のキャビティ２０が形成されるものを使用すればよい。射出成形用の可動型１２と固定型１３とにより形成されるキャビティ２０内にセットされた加飾用フィルム１は、キャビティ形成面１４を覆うことになる。キャビティ２０は樹脂成形品１８に孔部を形成するものであってもよい。キャビティ２０を形成する凹部は固定型１３あるいは可動型１２のいずれかに形成されていてもよい。可動型１２または固定型１３は、凹部の周囲で加飾用フィルム１を押さえ付けて固定するクランプ部材１５を有してもよい。クランプ部材１５は固定型１３あるいは可動型１２に設置されてもよい。
【００４５】
成形樹脂１７は、特に限定されることはない。たとえば、アクリル系樹脂、ポリスチレン系樹脂、ポリアクリロニトリルスチレン系樹脂、ポリアクリロニトリルブタジエンスチレン系樹脂などを用いることができる。また、自動車の内装部品や外装部品に用いられる代表的な成形樹脂１７としては、タルクを含有したポリプロピレン樹脂、変成ポリプロピレン樹脂などを挙げることができる。
【００４６】
次いで、型開きして加飾用フィルム１が一体化して接着された樹脂成形品１８を取り出す。加飾用フィルム１が転写材の場合は、基材フィルム２を剥離する。このようにして、成形同時加飾成形品を得ることができる。
【００４７】
なお、横型射出成形機の場合には、上記のとおりであるが、縦型射出成形機の場合には、固定型１３と可動型１２の関係が横型射出成形機の場合と逆になる。また、射出成形機の金型は２枚型の場合だけでなく、３枚型の場合にも同様に適用することができる。
【００４８】
【実施例】
＜実施例１＞ 基材フィルムを構成する樹脂成分として下記組成のポリカーボネート樹脂とポリブチレンテレフタレート樹脂を混練してコンパウンドした。この樹脂のＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が１０６℃であった。これをＴダイ押出し法により０．１８ｍｍの厚みの無延伸フィルムに成膜して基材フィルムを得た。
ポリカーボネート樹脂：
レキサン１３１（押出し加工グレード：日本ジーイープラス
チック株式会社製・熱変形温度 １３５℃） ６０重量部
ポリブチレンテレフタレート樹脂：
プラナック ＢＴ−１５００（押出し加工グレード：大日本イ
ンキ化学工業株式会社製・熱変形温度 ７０℃） ４０重量部
【００４９】
この基材フィルム上に、グラビアの印刷工程で５色の木目印刷を施し、一旦巻き取り後、さらにスクリーン印刷工程で接着層１色を含む計８色の車のインジケータ（メータ）部分を印刷した。グラビアの印刷工程での乾燥温度は７５℃、スクリーン印刷の乾燥温度は８０℃であった。各工程でのフィルム伸縮は基材フィルム全長の中でばらつくことなく０．３％未満におさえられたため、印刷での各色間での見当ずれがない加飾フィルムを得た。
【００５０】
以上のようにして得られた加飾フィルムを射出成形用の金型内にセットした後、加熱ヒーターにて２２０℃、１５秒間の条件で加熱し、フィルム表面温度が１０８℃となるようにした。この後真空引き行い、加飾フィルムの基材フィルム側が金型のキャビティ形成面に密着するように予備成形を行った。予備成形後の加飾フィルムは、均一に伸ばされており、インジケータパネル部分の文字変形がないものであった。また、加熱しすぎることがなく、真空工程で圧力による穴空きが発生することもなかった。しかも、印刷工程で使用される有機溶剤に基材フィルムが侵されていないため、加飾フィルムは予備成形に耐えるだけの強度を有していた。
【００５１】
型閉め後、アクリロニトリルブタジエンスチレン樹脂からなる成形樹脂をキャビティ内に射出し、成形樹脂を固化させて樹脂成形品を形成すると同時にその表面に加飾フィルムを一体化接着させ、木目パネルの中にインジケータ部分が存在する自動車用インジケータパネルを得た。このようにして得られたインジケータパネルは、印刷の見当ずれや文字変形のない美麗な加飾の施されたものであった。また、このインジケータパネルは、油よごれがついた場合に拭くエチルアルコール、中性洗剤に対してクラックの発生しないものであった。
【００５２】
＜実施例２＞ 基材フィルムを構成する樹脂成分として下記組成のポリカーボネート樹脂とアクリロニトリルブタジエンスチレン樹脂を混練してコンパウンドし、この樹脂のＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）を１１５℃とする以外は実施例１と同様の条件とした。
ポリカーボネート樹脂：
レキサン１３１（押出し加工グレード：日本ジーイープラス
チック株式会社製・熱変形温度 １３５℃） ７０重量部
アクリロニトリルブタジエンスチレン樹脂：
トヨラック９３０（透明グレード：東レ株式会社製・熱変形
温度８０℃） ３０重量部
【００５３】
実施例２でも、実施例１同様に印刷各工程でのフィルム伸縮は巻きの中でばらつくことなく０．３％未満におさえられたため、印刷での各色間での見当ずれがない加飾フィルムを得た。また、予備成形後の加飾フィルムは、均一な伸ばされており、インジケータパネル部分の文字変形や穴あきがないものであった。さらに、印刷工程で使用される有機溶剤に基材フィルムが侵されていないため、加飾フィルムは予備成形に耐えるだけの強度を有していた。結果、得られたインジケータパネルは、印刷の見当ずれや文字変形のない美麗な加飾の施されたものであった。また、このインジケータパネルは、油よごれがついた場合に拭くエチルアルコール、中性洗剤に対してクラックの発生しないものであった。
【００５４】
＜実施例３＞
基材フィルムを構成する樹脂成分として下記組成のポリカーボネート樹脂と共重合ポリエチレンテレフタレート樹脂を混練してコンパウンドし、この樹脂のＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）を１０３℃とする以外は実施例１と同様の条件とした。
ポリカーボネート樹脂：
レキサン１３１（押出し加工グレード：日本ジーイープラス
チック株式会社製・熱変形温度 １３５℃） ５５重量部
共重合ポリエチレンテレフタレート樹脂：
ＫＲ−５６０（シート用グレード：三菱レイヨン株式会社製・
熱変形温度６４℃） ４５重量部
【００５５】
実施例３でも、実施例１および実施例２同様に印刷各工程でのフィルム伸縮は巻きの中でばらつくことなく０．３％未満におさえられたため、印刷での各色間での見当ずれがない加飾フィルムを得た。また、予備成形後の加飾フィルムは、均一な伸ばされており、インジケータパネル部分の文字変形や穴あきがないものであった。さらに、印刷工程で使用される有機溶剤に基材フィルムが侵されていないため、加飾フィルムは予備成形に耐えるだけの強度を有していた。結果、得られたインジケータパネルは、印刷の見当ずれや文字変形のない美麗な加飾の施されたものであった。また、このインジケータパネルは、油よごれがついた場合に拭くエチルアルコール、中性洗剤に対してクラックの発生しないものであった。
【００５６】
＜実施例４＞
実施例１〜３と同じ印刷済みフィルムの基材フィルムの印刷面に、ポリプロピレン （ノバテックＰＰ ＭＡ３：日本ポリケム株式会社製・熱変形温度６８℃）の０．３５ｍｍの厚みのフィルムをバッキングシートとしてドライラミネートで貼り合せ加飾フィルムを得、実施例１〜３と同様の方法で目パネルの中にインジケータ部分が存在する自動車用インジケータパネルを得た。予備成形後の加飾フィルムは、均一な伸ばされており、インジケータパネル部分の文字変形や穴あきがないものであった。また、得られたインジケータパネルは、印刷の見当ずれや文字変形のない美麗な加飾の施されたものであった。また、このインジケータパネルは、油よごれがついた場合に拭くエチルアルコール、中性洗剤に対してクラックの発生しないものであった。
【００５７】
＜比較例＞
実施例で使用したポリカーボネート樹脂であるレキサン１３１（押出し加工グレード：日本ジーイープラスチック株式会社製・熱変形温度 １３５℃）のみを用い、Ｔダイ押出し法により０．１８ｍｍの厚みの無延伸フィルムに成膜して基材フィルムを得た。
【００５８】
印刷工程は実施例と同様とした。印刷工程での問題は実施例と同様に問題なかった。
【００５９】
この加飾フィルムを用い、実施例と同じ条件で予備成形を行ったが、フィルムの絞り性が悪く、ヒータ温度を徐々に上げた。ヒータ温度が３２０℃で１５秒加熱した時にようやく加飾フィルムは実施例と同様の絞り程度になった。しかし、加飾フィルムにかかる温度が安定しないためか、１０枚中３枚は部分的に加熱しすぎの部分で印刷の変形がみられかつ、１枚は後の真空工程で圧力による穴空きが発生した。また、１枚は印刷工程で使用される有機溶剤に基材フィルムが侵されて脆くなってたためか、予備成形中に破断した。結果、得られたインジケータパネルは、印刷の見当ずれや文字変形、加飾フィルムが破損した部分があった。また、得られたインジケータパネルは、実施例と同様のエチルアルコール、中性洗剤に対してクラックが発生した。
【００６０】
【発明の効果】
本発明は、前記した構成からなるので、次のような効果を奏する。
【００６１】
本発明の加飾用フィルムは、基材フィルム上に印刷工程を経て少なくとも図柄層が形成され射出成形用の金型内にセットされて成形樹脂の表面に一体化接着される加飾用フィルムであって、基材フィルムを構成する樹脂成分としてポリカーボネート樹脂と、アクリロニトリルブタジエンスチレン、ポリブチレンテレフタレート、ポリエチレンテレフタレートおよびこれらの変性樹脂のうち少なくとも１つとを用い、且つ基材フィルムのＡＳＴＭ−Ｄ６４８法（１．８２ＭＰａ）による熱変形温度（荷重たわみ温度）が８５〜１２０℃のものを用いるので、耐溶剤性及び耐薬品性が向上し、且つ予備成形時の熱成形性のよいものである。
【図面の簡単な説明】
【図１】本発明に係る加飾用フィルムの一実施例を示す断面図である。
【図２】本発明に係る加飾用フィルムの印刷工程の一実施例を示す図である。
【図３】本発明に係る加飾用フィルムの一実施例を示す断面図である。
【図４】本発明に係る加飾用フィルムを用いた成形同時加飾工程の一実施例を示す図である。
【図５】本発明に係る加飾用フィルムを用いた成形同時加飾工程の一実施例を示す図である。
【図６】本発明に係る加飾用フィルムを用いた成形同時加飾工程の一実施例を示す図である。
【図７】本発明に係る加飾用フィルムを用いた成形同時加飾工程の一実施例を示す図である。
【図８】本発明に係る加飾用フィルムを用いた成形同時加飾工程の一実施例を示す図である。
【符号の説明】
１ 加飾用フィルム
２ 基材フィルム
３ 図柄層
４ バッキングシート
５ 巻出部
６ インキパン
７ 版胴
８ 圧胴
９ 乾燥部
１０ 巻取部
１１ ガイドロール
１２ 可動型
１３ 固定型
１４ キャビティ形成面
１５ クランプ部材
１６ ゲート部
１７ 成形樹脂
１８ 樹脂成形品
１９ 真空吸引孔
２０ キャビティ
２１ 加熱板[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative film for decorating three-dimensional resin molded products such as automobile indicator panels and home appliance audio panels, and more particularly to a film used for decorating a deep drawing shape.
[0002]
[Prior art]
After obtaining a decorative film by printing a design on a base film as a method for obtaining an automotive indicator panel or an audio panel for home appliances, supplying it into an injection mold and molding a three-dimensional molded product At the same time, there is a molding simultaneous decorating method in which a decoration film is integrally bonded to a molded product for decoration. As a base film for the decorative film, conventionally, an unstretched polycarbonate film having a heat resistance (thermal deformation temperature of 135 to 150 ° C.) has been used (see JP-A-2-215511).
[0003]
Since this unstretched polycarbonate film has heat resistance, even if it is subjected to drying heat (mainly 60 to 80 ° C.) in the process of providing a printed layer such as a design layer, the dimensional change of the base film is small (see FIG. 2). Therefore, the pattern pattern printed on the base film is less likely to be distorted, and each color pattern is easily registered in the multicolor printing process.
[0004]
Then, before or after supplying such a decorative film into the injection mold, the cavity forming surface of the movable mold of the injection mold by pre-molding such as vacuum forming or vacuum / pressure forming When processing into a three-dimensional shape so as to follow, the non-stretched polycarbonate film has heat resistance, so that the surface temperature of the heater such as the heating plate 21 is set to 300 ° C. to 400 ° C. so that it can be easily processed. It is common to heat (see FIG. 5).
[0005]
[Problems to be solved by the invention]
However, the base film made of the polycarbonate resin has a problem that it is extremely inferior in solvent resistance and chemical resistance. If the solvent resistance and chemical resistance are inferior, the organic solvent used in the printing process is fragile and brittle, and is easily broken during preforming. Further, if the surface is wiped with a material containing detergent or alcohol after being integrally bonded to the surface of the molded product, cracks are likely to occur.
[0006]
Further, in the case of high temperature heating, since the difference between the heater and the outside air temperature is large, the heat radiation at the outer periphery of the heater is intense, and it is difficult to control the entire surface of the decorative film to be heated uniformly. In addition, since the difference between the heater and the outside air temperature is large, it is easy for the heater to dissipate heat when the wind generated by convection or movement of the heater hits it, and it is difficult to control the temperature applied to the decorative film at any time. is there. Therefore, when preforming such as vacuum forming or vacuum / pressure forming in such a heated state, the easiness of elongation of the decorative film varies depending on the part, or the easiness of elongating varies between individual preforms. There was a problem in thermoformability. Alternatively, it was sometimes heated too much and evacuated to create holes.
[0007]
Therefore, the present invention eliminates the above-described problems, improves solvent resistance and chemical resistance, and uses a base film with good thermoformability at the time of preforming, for simultaneous molding decoration. An object is to provide a decorative film that can be deep-drawn to be used.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the decorative film of the present invention is formed on at least a pattern layer on a base film through a printing process and set in a mold for injection molding so as to be integrated with the surface of the molding resin. A decorative film to be bonded, polycarbonate resin as a resin component constituting the base film, At least one of acrylonitrile butadiene styrene, polybutylene terephthalate, polyethylene terephthalate and their modified resins; And a base film having a thermal deformation temperature (deflection temperature under load) of 85 to 120 ° C. according to ASTM-D648 method (1.82 MPa) is used.
[0009]
Moreover, in the said structure, about the resin component which comprises a base film, A polycarbonate resin and at least one of acrylonitrile butadiene styrene, polybutylene terephthalate, polyethylene terephthalate and their modified resins; The weight composition ratio is 82:19 to 38:62.
[0010]
Moreover, in each said structure, the ASTM-D648 method ( 1.82 A backing sheet having a thermal deformation temperature (deformation temperature under load) of 120 ° C. or less was laminated.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described in detail with reference to the drawings.
[0012]
1 and 3 are cross-sectional views showing an embodiment of a decorative film according to the present invention, FIG. 2 is a view showing an embodiment of a printing process of the decorative film, and FIGS. 4 to 8 are decorative films. It is a figure which shows one Example of the shaping | molding simultaneous decorating process using the. In the figure, 1 is a decorative film, 2 is a base film, 3 is a design layer, 4 is a backing sheet, 5 is an unwinding part, 6 is an ink pan, 7 is a plate cylinder, 8 is an impression cylinder, and 9 is a drying part. 10 is a winding part, 11 is a guide roll, 12 is a movable mold, 13 is a fixed mold, 14 is a cavity forming surface, 15 is a clamp member, 16 is a gate part, 17 is a molded resin, 18 is a resin molded product, 19 Denotes a vacuum suction hole, 20 denotes a cavity, and 21 denotes a heating plate.
[0013]
The decorative film 1 of the present invention is a process in which at least a design layer 3 is formed on a base film 2 through a printing process, set in a mold for injection molding, and integrally bonded to the surface of a molding resin 17. It is a decorative film (see FIG. 1).
[0014]
The base film 2 is made of a polycarbonate resin and a resin other than the polycarbonate resin as the resin component. The base film 2 having such a resin component can provide a decorative film having improved solvent resistance and chemical resistance as compared with a base film made of a conventional polycarbonate resin alone. In the present invention, the polycarbonate resin is a general term for compounds having a carbonate type structure in the structural unit represented by the following chemical formula 1, and refers to an aromatic polycarbonate here. In particular, poly-4,4'-isopropylene diphenyl carbonate (Chemical Formula 2) is used as an aromatic polycarbonate.
[0015]
[Chemical 1]

[0016]
[Chemical 2]

[0017]
Moreover, as resin other than the said polycarbonate resin which comprises the base film 2 with polycarbonate resin, For example, AAS (acrylonitrile / acrylic rubber / styrene), EEA (ethylene / acrylic acid ester), ABS (acrylonitrile butadiene styrene), ACS (acrylonitrile / chlorinated polyethylene / styrene), PEN (polyethylene naphthalate), PBT (polybutylene) Polyester resins such as terephthalate) and PET (polyethylene terephthalate), and modified ones thereof can be used, but are not particularly limited as long as they are resins other than polycarbonate resins. Solvent resistant to the extent that it is hardly attacked by the organic solvent used in the printing process and to the extent that no cracks occur even if the surface is wiped with a substance containing detergent or alcohol after being integrally bonded to the surface of the molded product. In order to greatly improve the property and chemical resistance, the weight composition ratio between the polycarbonate resin and the resin other than the polycarbonate resin is 85:15, or the ratio of the resin other than the polycarbonate resin is higher than the weight composition ratio. To be mixed.
[0018]
Moreover, the base film 2 is the ASTM-D648 method ( 1.82 A material having a heat deformation temperature (a deflection temperature under load) of 85 to 120 ° C. is used. By using the base film 2 having such characteristics, a decorative film having both dimensional stability during printing and thermoformability during preforming can be obtained.
[0019]
Considering the dimensional stability at the time of printing of the decorative film, the base film 2 is dried and heated at 60 to 80 ° C. in the process of providing a printing layer such as the design layer 3 on the base film 2 and is a long base film 2. When printing on a machine with a winding device (called roll-to-roll), a material that does not undergo dimensional change under tension such as winding, or a small amount of dimensional change may occur, but the change is constant Must be material controlled by quantity. As a result of the inventor trying to print and dry the base film 2 having various heat distortion temperatures, the ASTM-D648 method ( 1.82 A material having a heat deformation temperature (a deflection temperature under load) of 85 to 120 ° C. is used. It has been found that if a thermal deformation temperature (deflection temperature under load) due to such characteristics is 85 ° C. or higher, dimensional stability during the printing process can be obtained. In addition, dimensional change here means that expansion and contraction other than thermal expansion occurs 1% or more with respect to the original length.
[0020]
On the other hand, considering the thermoformability at the time of preforming the decorative film, the base film 2 is made of a material that requires less heat to be applied during the preforming so that the difference between the heater and the outside air temperature does not increase. There must be. As a result of pre-molding of the decorative film having the base film 2 having various heat distortion temperatures by the present inventor, the ASTM-D648 method ( 1.82 If the heat deformation temperature (deformation temperature under load) of 120 MPa or less is used, the difference between the heater and the outside air temperature can be made sufficiently small at the time of preforming. Does not vary depending on the individual pre-molding, and does not vary in easiness of stretching, and there is no hole due to evacuation in a partially heated state. It turns out that you can get.
[0021]
The above ASTM-D648 method ( 1.82 (MPa) is a base film 2 having a thermal deformation temperature (deflection temperature under load) of 85 to 120 ° C. As a resin other than the polycarbonate resin used for the base film 2, acrylonitrile butadiene styrene, polybutylene terephthalate, polyethylene terephthalate In addition, it was found that a resin having a weight composition ratio of 82:19 to 38:62 between the polycarbonate resin and the resin other than the polycarbonate resin using at least one of these modified resins is suitable.
[0022]
When the proportion of the polycarbonate resin is greater than the above weight composition ratio 82:19, the deflection temperature under load according to ASTM-D648 method of the base film becomes higher than 120 ° C, and the film of the polycarbonate resin alone (the deflection temperature under load is 125 to 150 ° C). Near heat resistance. That is, sufficient thermoformability at the time of preforming cannot be obtained. On the other hand, when the proportion of the polycarbonate resin is less than the above weight composition ratio 38:62, the deflection temperature under load according to the ASTM-D648 method of the base film 2 becomes lower than 85 ° C., and the drying heat (mainly 60 to 85 in the printing process). The dimensional stability of the base film 2 with respect to (° C.) cannot be sufficiently obtained.
[0023]
Moreover, it is preferable to make the thickness of the said base film into the range of 0.05-1 mm. If the thickness is less than 0.05mm, the film is too thin when it is pre-molded outside the mold for injection molding and supplied into the mold. This is because it is difficult to handle. Further, if the thickness exceeds 1 mm, there are many problems that the printing press cannot handle, and there is a problem that printing becomes difficult.
[0024]
Moreover, it is preferable to use an unstretched film for the base film of the present invention. An unstretched film is also referred to as an unstretched film, and refers to a film that does not intentionally undergo a stretching process during film formation. In addition, when the base film is manufactured in a long length, since there is a winding process at the end, it takes some stretching in the direction of winding the base film. To. In general, a stretched film is crystallized in the film by stretching, and its mechanical strength is too strong. For this reason, a decorative film using a stretched film as a base film is difficult to be preformed, and is not particularly suitable for deep drawing. In contrast, an unstretched film is not stretched, so that crystallization does not proceed and mechanical strength is not too strong. Therefore, a decorative film using an unstretched film as a base film is easy to preform and deep drawing is easy. For the production of an unstretched film, a T-die extrusion method, a calendar method, a casting method, or the like can be used.
[0025]
The ASTM-D648 method ( 1.82 (MPa) is a measurement method similar to JIS K-6871 (18.6 kg). Therefore, the decorative film 1 of the present invention has a heat distortion temperature (18.6 kg) of the base film 2 according to JIS K-6871 (18.6 kg). The deflection temperature under load) may be 85 to 120 ° C.
[0026]
As the decorative film 1 used in the present invention, a transfer material or an insert material can be used.
[0027]
The insert material is obtained by forming the design layer 3 and the like on the base film 2.
[0028]
The pattern layer 3 may be formed by printing a pattern on one or both of the front surface and the back surface of the base film 2. The pattern layer 3 is usually formed as a printing layer. Materials for the printing layer include urethane resin, vinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, alkyd resin, heat A colored ink containing a resin such as a plastic elastomer, preferably a resin capable of forming a flexible film as a binder, and an appropriate color pigment or dye as a colorant may be used. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. In particular, the offset printing method and the gravure printing method are suitable for performing multicolor printing and gradation expression. For example, in the case of gravure rotation, for example, the main flow of printing is as follows. After a sheet to be printed is continuously fed out from the unwinding unit 5, ink is first supplied from the ink pan 6 to the surface in the first printing unit. By passing the sheet between the rotating plate cylinder 7 and the impression cylinder 8 that applies pressure to the plate cylinder 7, ink is transferred onto the sheet to form a printing layer, and the sheet is subsequently transferred to the steam drum. What is the process of drying the printed layer by passing it through a drying unit 9 such as hot air or cold air, and then sending the sheet to the next printing unit and forming another printed layer on the sheet in the same manner as the previous printing unit? Repeatedly, after forming all the printing layers, the sheet is wound around the winding unit 10. In addition, what is necessary is just to finely adjust tension | tensile_strength with many guide rolls 11 for registration. In any printing method, in order to dry the solvent and thinner in the ink, the printed layer is not dried naturally but is heated. The decorative film 1 of the present invention is a base film ASTM-D648 method ( 1.82 (MPa) is used with a heat deformation temperature (deflection temperature under load) of 85 to 120 ° C., so that the pattern pattern printed on the base film is distorted or multicolored even by the drying heat during printing. There is no difficulty in registering each color pattern in the printing process.
[0029]
The design layer 3 may be a printed layer alone or may be a combination of a printed layer and a metal thin film layer. The metal thin film layer is for expressing the metallic luster as the pattern 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 depending on the metallic luster color to be expressed. As an example of forming a partial metal thin film layer, a solvent-soluble resin layer is formed on a portion that does not require the metal thin film layer, and then a metal thin film is formed on the entire surface, followed by solvent cleaning. There is a method of removing an unnecessary metal thin film together with a 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 then formed on a portion where the metal thin film is to be left, and etching is performed with acid or alkali to remove the resist layer. .
[0030]
Further, an adhesive layer may be formed. The adhesive layer adheres the insert material to the molding resin 17, and is formed on the design layer 3 side or the base film 2 side of the decorative film 1 as necessary. As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the molding resin 17 is appropriately used. For example, when the material of the molding resin 17 is an acrylic resin, an acrylic resin may be used. In addition, when the material of the molding resin 17 is polyphenylene oxide / polystyrene resin, polycarbonate resin, styrene copolymer resin, or polystyrene blend resin, acrylic resin, polystyrene resin, polyamide having affinity with these resins A series resin or the like may be used. Furthermore, when the material of the molding resin 17 is a polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used. Examples of the method for forming the adhesive layer include a coating method such as a gravure coating method, a roll coating method and a comma coating method, a printing method such as a gravure printing method and a screen printing method.
[0031]
Moreover, you may laminate | stack the backing sheet 4 on the base film which passed through the said printing process (refer FIG. 3). The backing sheet 4 is used when the decorative film 1 is given waist strength and the decorative film is preformed outside the mold for injection molding or when the decorative film is supplied into the injection mold. It is for facilitating handling and fusing with injection molding resin. However, the backing sheet 4 uses a film having a heat deformation temperature (a deflection temperature under load) of 120 ° C. or less according to the ASTM-D648 method (1820 MPa). When the thermal deformation temperature of the backing sheet 4 exceeds 120 ° C., a high temperature is required for preforming the decorative film, and the stretchability of the decorative film varies depending on the part, and it can be easily stretched by individual preforming. This is because there are variations in thickness. In addition, since the backing sheet 4 of the present invention does not go through the printing process, the deformation temperature (the deflection temperature under load) need not be 85 ° C. or higher. The above ASTM-D648 method ( 1.82 As the backing sheet 4 having a heat deformation temperature (deformation temperature under load) of 120 MPa or less, for example, a polypropylene (heat deformation temperature 49 to 60 ° C.) resin or the like may be used.
[0032]
Next, the case where the decorating film 1 is used as a transfer material will be described. The transfer material is obtained by providing a transfer layer composed of a release layer, a design layer 3, an adhesive layer and the like on the base film 2.
[0033]
As the base film 2, the same material as in the case of the insert material can be used. In order to improve the peelability of the transfer layer from the base film 2, the release layer may be formed on the entire surface before the transfer layer is provided on the base film 2. The release layer is released from the transfer layer together with the base film 2 when the base film 2 is peeled off after the transfer. As the material of the release layer, melamine resin release agent, silicone resin release agent, fluororesin release agent, cellulose derivative release agent, urea resin release agent, polyolefin resin release agent, Paraffin-type release agents and composite release agents thereof can be used. As a method for forming the release layer, there are a coating method such as a roll coating method and a spray coating method, a printing method such as a gravure printing method and a screen printing method.
[0034]
The release layer is formed entirely or partially on the base film 2 or the release layer. The release layer is a layer that peels from the base film 2 or the release layer and becomes the outermost surface of the transfer object when the base film 2 is peeled after transfer. The release layer can be made of acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, or vinyl chloride-vinyl acetate copolymer system. A copolymer such as a resin or an ethylene-vinyl acetate copolymer resin may be used. When the release layer requires hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used. The release layer may be colored or uncolored. As a method for forming the release layer, there are a coating method such as a gravure coating method, a roll coating method and a comma coating method, a printing method such as a gravure printing method and a screen printing method.
[0035]
The pattern layer 3 may be provided in the same manner as in the case of the insert material.
[0036]
The adhesive layer adheres each of the above layers to the surface of the molding resin 17. The adhesive layer is formed on a portion to be bonded. That is, when the part to be bonded is the entire surface, an adhesive layer is formed on the entire pattern layer 3. If the part to be bonded is partial, an adhesive layer is partially formed on the design layer 3. The adhesive layer may be provided in the same manner as in the case of the insert material.
[0037]
Next, a method for producing a simultaneously molded decorative molded product will be described.
[0038]
First, the decorative film 1 is set on the surface of the movable mold 12 which is an injection mold (see FIG. 4).
[0039]
As a specific example of how to set the movable mold 12, a long decorative film 1 is temporarily wound around a roll shaft to form a roll-shaped roll, and this roll-shaped scroll is placed on the upper part of the movable mold 12 for injection molding. The movable mold 12 is placed so as to be movable integrally with the movable mold 12, and the decorative film 1 is unwound from the roll-shaped scroll while passing between the retracted movable mold 12 and the fixed mold 13 so that the movable mold for injection molding is used. What is necessary is just to wind up the film 1 for decorating with the roll axis | shaft of the film winding means installed in the lower part of 12 so that the movable mold | type 12 could move integrally. As another example, a sheet of decorative film 1 may be used and set on the surface of the movable mold 12 by a robot or manually. When the decorative film 1 is set on the surface of the movable mold 12, the decorative film 1 is arranged on the surface of the movable mold 12, and then the position of the decorative film 1 with respect to the surface of the movable mold 12 is determined by a positioning sensor or the like. The decorative film 1 may be pressed against the surface of the movable mold 12 for injection molding by the clamp member 15.
[0040]
Next, after the decorative film 1 is set on the surface of the movable mold 12 for injection molding, the decorative film 1 is moved by using the vacuum suction holes 19 formed in the movable mold 12 for injection molding. Then, vacuum suction is performed along the cavity forming surface 14 of 12 to perform preforming along the concave portion of the movable mold 12 for injection molding, that is, along the cavity forming surface 14 of the cavity 20 (see FIG. 5). As a specific example, the decorative film 1 set on the surface of the movable mold 12 is heated and softened by a heater such as a heating plate 21 inserted between the movable mold 12 and the fixed mold 13, and is used for injection molding. The space between the concave portion of the movable mold 12 and the decorative film 1 is sealed, exhausted from the vacuum suction hole 19 and vacuum sucked, and applied to the inner surface of the concave portion (cavity forming surface 14) of the movable mold 12 for injection molding. There is a method of closely attaching the decorative film 1. When performing preforming or pressing and fixing the decorative film 1 with the clamp member 15, unnecessary portions of the decorative film 1 may be punched. The decorative film 1 of the present invention is a base film ASTM-D648 method ( 1.82 Since the one having a heat deformation temperature (deflection temperature under load) of 85 to 120 ° C. is used, the difference between the heater and the outside air temperature can be sufficiently reduced during the preforming, and as a result, the decorating film is easily stretched. Does not vary from part to part, and there is no variation in easiness of elongation between individual preforms. In addition, there is no possibility that a hole is formed by vacuuming due to partial heating.
[0041]
Instead of the above method, before setting the decorative film 1 on the surface of the movable mold 12 for injection molding, a three-dimensional machining mold different from the movable mold 12 for injection molding and the fixed mold 13 is used. The decorative film 1 is preformed into a desired three-dimensional shape in advance, and after punching into a desired shape, the preformed decorative film 1 is inserted into the recess of the movable mold 12 for injection molding. Alternatively, see FIG. Examples of the desired three-dimensional shape include a shape matching the cavity forming surface 14 of the movable mold 12 for injection molding or the fixed mold 13. As a method of processing into a three-dimensional shape, there are a vacuum forming method, a pressure forming method, and a pressure forming method in which heated rubber is pressed. As a method of punching into a desired shape, there are a Thomson punching method, a press method using a die, and the like. As the punching shape, there are a line along the outer periphery of a predetermined shape, a hole of a predetermined shape, and the like. In addition, you may punch at the same time when processing to a three-dimensional shape.
[0042]
Next, the movable mold 12 is closed with respect to the fixed mold 13, and the molten molding resin 17 is injected into the cavity 20 from the gate portion 16 of the fixed mold 13, and the molding resin 17 is solidified to be within the cavity 20. At the same time as the resin molded product 18 is formed, the decorative film 1 is integrally bonded to the surface (see FIG. 7).
[0043]
Thereafter, after the resin molded product 18 is taken out from the movable mold 12, unnecessary portions of the decorative film 1 adhered to the resin molded product 18 are removed (see FIG. 8). In addition, when it punched in a desired shape previously as mentioned above, the operation | work which removes the unnecessary part of the film 1 for decorating is unnecessary.
[0044]
The movable mold 12 and the fixed mold 13 as injection molds are not particularly limited to the above-described embodiment, and are constituted by the fixed mold 13 and the movable mold 12 having the gate portion 16 for injecting the molding resin 17. Then, the fixed mold 13 and the movable mold 12 may be closed so that one or a plurality of cavities 20 surrounded by the cavity forming surface 14 of the fixed mold 13 and the movable mold 12 are formed. . The decorative film 1 set in the cavity 20 formed by the movable mold 12 for injection molding and the fixed mold 13 covers the cavity forming surface 14. The cavity 20 may form a hole in the resin molded product 18. The recess forming the cavity 20 may be formed in either the fixed mold 13 or the movable mold 12. The movable mold 12 or the fixed mold 13 may have a clamp member 15 that presses and fixes the decorative film 1 around the recess. The clamp member 15 may be installed on the fixed mold 13 or the movable mold 12.
[0045]
The molding resin 17 is not particularly limited. For example, an acrylic resin, a polystyrene resin, a polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin, or the like can be used. Moreover, as a typical molding resin 17 used for interior parts and exterior parts of automobiles, there can be mentioned polypropylene resin containing talc, modified polypropylene resin, and the like.
[0046]
Next, the mold is opened, and the resin molded product 18 to which the decorative film 1 is integrated and bonded is taken out. When the decorative film 1 is a transfer material, the base film 2 is peeled off. In this way, a simultaneously molded decorative molded product can be obtained.
[0047]
In the case of a horizontal injection molding machine, it is as described above. However, in the case of a vertical injection molding machine, the relationship between the fixed mold 13 and the movable mold 12 is opposite to that in the case of a horizontal injection molding machine. Moreover, the mold of the injection molding machine can be similarly applied not only to the case of two sheets but also to the case of three sheets.
[0048]
【Example】
<Example 1> A polycarbonate resin and a polybutylene terephthalate resin having the following composition were kneaded and compounded as resin components constituting the base film. ASTM-D648 method of this resin ( 1.82 (MPa), the heat distortion temperature (deflection temperature under load) was 106 ° C. This was formed into an unstretched film having a thickness of 0.18 mm by a T-die extrusion method to obtain a base film.
Polycarbonate resin:
Lexan 131 (extrusion grade: Nihon GE Plus)
60 parts by weight manufactured by Chick Co., Ltd. (heat distortion temperature 135 ° C)
Polybutylene terephthalate resin:
Planac BT-1500 (extrusion processing grade: Dainippon
40 parts by weight, manufactured by NKI CHEMICAL INDUSTRIES CO., LTD.
[0049]
On this base film, 5 colors of wood grain printing was performed in the gravure printing process, and after winding up, a total of 8 color car indicator (meter) parts including 1 color of the adhesive layer were printed in the screen printing process. . The drying temperature in the gravure printing process was 75 ° C., and the drying temperature in screen printing was 80 ° C. Since the film expansion and contraction in each step was suppressed to less than 0.3% without variation in the entire length of the base film, a decorative film having no misregistration between colors in printing was obtained.
[0050]
After the decorative film obtained as described above was set in a mold for injection molding, it was heated with a heater at 220 ° C. for 15 seconds so that the film surface temperature became 108 ° C. . Thereafter, vacuuming was performed, and preforming was performed so that the base film side of the decorative film was in close contact with the cavity forming surface of the mold. The decorative film after the preforming was stretched uniformly, and there was no character deformation of the indicator panel portion. Moreover, it did not heat too much and the vacancy by pressure did not generate | occur | produce in the vacuum process. Moreover, since the base film is not attacked by the organic solvent used in the printing process, the decorative film has sufficient strength to withstand the preforming.
[0051]
After closing the mold, a molding resin made of acrylonitrile butadiene styrene resin is injected into the cavity, and the molding resin is solidified to form a resin molded product. An automotive indicator panel with a part was obtained. The indicator panel thus obtained was beautifully decorated without printing misregistration or character deformation. Further, this indicator panel did not generate cracks with respect to ethyl alcohol or a neutral detergent that was wiped when oil was dirty.
[0052]
<Example 2> As a resin component constituting the base film, a polycarbonate resin having the following composition and an acrylonitrile butadiene styrene resin are kneaded and compounded, and the resin is subjected to ASTM-D648 method ( 1.82 The conditions were the same as in Example 1 except that the heat distortion temperature (deformation temperature under load) was 115 ° C.
Polycarbonate resin:
Lexan 131 (extrusion grade: Nihon GE Plus)
70 parts by weight manufactured by Chick Co., Ltd. (heat distortion temperature 135 ° C)
Acrylonitrile butadiene styrene resin:
Toyolac 930 (Transparent grade: Toray Industries, Inc., thermal deformation
30 parts by weight)
[0053]
In Example 2, as in Example 1, the film expansion and contraction in each printing step was suppressed to less than 0.3% without variation in the winding, so a decorative film with no misregistration between colors in printing was obtained. Obtained. Moreover, the decorative film after preforming was uniformly stretched, and there was no character deformation or perforation of the indicator panel portion. Furthermore, since the base film was not attacked by the organic solvent used in the printing process, the decorative film had a strength sufficient to withstand the preforming. As a result, the obtained indicator panel was beautifully decorated without misregistration of printing and character deformation. Further, this indicator panel did not generate cracks with respect to ethyl alcohol or a neutral detergent that was wiped when oil was dirty.
[0054]
<Example 3>
As a resin component constituting the base film, a polycarbonate resin of the following composition and a copolymerized polyethylene terephthalate resin are kneaded and compounded, and this resin is subjected to ASTM-D648 method ( 1.82 The conditions were the same as in Example 1 except that the heat distortion temperature (deformation temperature under load) was 103 ° C.
Polycarbonate resin:
Lexan 131 (extrusion grade: Nihon GE Plus)
55 parts by weight manufactured by Chick Co., Ltd. (heat distortion temperature 135 ° C)
Copolyethylene terephthalate resin:
KR-560 (grade for sheet: manufactured by Mitsubishi Rayon Co., Ltd.)
45 parts by weight)
[0055]
In Example 3 as well as Example 1 and Example 2, the film expansion and contraction in each printing step was suppressed to less than 0.3% without variation in the winding, so there was no misregistration between colors in printing. A decorative film was obtained. Moreover, the decorative film after preforming was uniformly stretched, and there was no character deformation or perforation of the indicator panel portion. Furthermore, since the base film was not attacked by the organic solvent used in the printing process, the decorative film had a strength sufficient to withstand the preforming. As a result, the obtained indicator panel was beautifully decorated without misregistration of printing and character deformation. Further, this indicator panel did not generate cracks with respect to ethyl alcohol or a neutral detergent that was wiped when oil was dirty.
[0056]
<Example 4>
On the printing surface of the base film of the same printed film as in Examples 1 to 3, a 0.35 mm thick film of polypropylene (Novatech PP MA3: manufactured by Nippon Polychem Co., Ltd., heat distortion temperature 68 ° C.) is dried as a backing sheet. A laminated decorative film was obtained by lamination, and an automotive indicator panel in which an indicator portion was present in the eye panel was obtained in the same manner as in Examples 1 to 3. The decorative film after preforming was uniformly stretched, and there was no character deformation or perforation in the indicator panel portion. Further, the obtained indicator panel was beautifully decorated without misprinting or character deformation. Further, this indicator panel did not generate cracks with respect to ethyl alcohol or a neutral detergent that was wiped when oil was dirty.
[0057]
<Comparative example>
Using only Lexan 131 (extrusion processing grade: Nippon GE Plastics Co., Ltd., heat distortion temperature 135 ° C.), which is a polycarbonate resin used in the Examples, a film was formed on an unstretched film having a thickness of 0.18 mm by a T-die extrusion method. Thus, a base film was obtained.
[0058]
The printing process was the same as in the example. There were no problems in the printing process as in the examples.
[0059]
Using this decorative film, preforming was performed under the same conditions as in the Examples, but the drawability of the film was poor and the heater temperature was gradually raised. When the heater temperature was 320 ° C. and heated for 15 seconds, the decorative film finally became the same aperture as in the examples. However, because the temperature applied to the decorative film is not stable, 3 out of 10 sheets are partially heated too much, and printing deformation is observed in one part, and one sheet has holes due to pressure in the subsequent vacuum process Occurred. In addition, one of the sheets broke during the pre-molding because the base film was damaged by the organic solvent used in the printing process. As a result, the obtained indicator panel had a part where the misregistration of printing, character deformation, and the decorative film were damaged. Also, In the obtained indicator panel, cracks occurred in the same ethyl alcohol and neutral detergent as in the examples.
[0060]
【The invention's effect】
Since this invention consists of an above-described structure, there exist the following effects.
[0061]
The decorative film of the present invention is a decorative film in which at least a design layer is formed on a base film through a printing process, is set in a mold for injection molding, and is integrally bonded to the surface of a molding resin. And a polycarbonate resin as a resin component constituting the base film, At least one of acrylonitrile butadiene styrene, polybutylene terephthalate, polyethylene terephthalate and their modified resins; Is used, and the base film has a heat deformation temperature (deflection temperature under load) of 85 to 120 ° C. according to ASTM-D648 method (1.82 MPa), so that the solvent resistance and chemical resistance are improved, and It has good thermoformability during molding.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a decorative film according to the present invention.
FIG. 2 is a diagram showing an example of a printing process of a decorative film according to the present invention.
FIG. 3 is a cross-sectional view showing an example of a decorative film according to the present invention.
FIG. 4 is a view showing an example of a simultaneous molding and decorating process using the decorative film according to the present invention.
FIG. 5 is a view showing one example of a simultaneous molding and decorating step using the decorative film according to the present invention.
FIG. 6 is a view showing one example of a simultaneous molding and decorating step using the decorative film according to the present invention.
FIG. 7 is a diagram showing an example of a simultaneous molding and decorating process using the decorating film according to the present invention.
FIG. 8 is a view showing one example of a simultaneous molding and decorating step using the decorative film according to the present invention.
[Explanation of symbols]
1 Decorating film
2 Base film
3 design layers
4 backing sheet
5 Unwinding part
6 Ink pan
7 Plate cylinder
8 impression cylinder
9 Drying section
10 Winding part
11 Guide roll
12 Movable type
13 Fixed type
14 Cavity forming surface
15 Clamp member
16 Gate part
17 Molding resin
18 resin molded products
19 Vacuum suction hole
20 cavities
21 Heating plate

Claims (3)

A decorative film that is formed on at least a pattern layer on a base film through a printing process, is set in a mold for injection molding and is integrally bonded to the surface of a molding resin, and constitutes the base film A polycarbonate resin, acrylonitrile butadiene styrene, polybutylene terephthalate, polyethylene terephthalate and at least one of these modified resins are used as a resin component, and the base film is subjected to a heat deformation temperature (load) according to ASTM-D648 method (1.82 MPa). A film for decorating capable of deep drawing, which is used for simultaneous molding, characterized by using a film having a deflection temperature of 85 to 120 ° C. Regarding the resin component constituting the substrate film, the weight composition ratio of the polycarbonate resin to acrylonitrile butadiene styrene, polybutylene terephthalate, polyethylene terephthalate and at least one of these modified resins is 82:19 to 38:62. A film for decorating that can be deep-drawn, which is used for simultaneous molding of the item 1.   The backing film having a thermal deformation temperature (load deflection temperature) of 120 ° C. or less by the ASTM-D648 method (1.82 MPa) is laminated on the base film that has undergone the printing process. The film for decorating which can be deep-drawn used for the simultaneous molding decoration described in 1.

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