JP4031305B2 - Method for producing insert sheet having fine uneven pattern, and method for producing insert molded product having fine uneven pattern - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing an insert sheet having fine irregularities and a method for producing an insert molded article having fine irregularities, which are used for housings of home appliances and communication devices.
[0002]
[Prior art]
Conventionally, for the purpose of decorating the surface of a resin molded product, an insert sheet 7 provided with a decorative layer 6 on one side of a transparent substrate sheet 1 is placed in an injection mold 9 having a desired cavity shape. After the mold clamping, the resin is injected and filled in the cavity 13 from the decorative layer 6 side of the insert sheet 7 and cooled to obtain a resin molded product, and at the same time, the insert sheet 7 is integrated on the surface. I'm.
[0003]
By the way, in the manufacturing method of the said insert molded product, when providing a fine unevenness | corrugation pattern partially on the surface of an insert molded product, a fine unevenness process is given to the surface which touches the insert sheet 7 of the metal mold | die 9 for injection molding, and injection molding is carried out. Occasionally, the surface of the insert molded product was shaped by the fine irregularities 9a of the injection mold 9 (see FIGS. 15 and 16).
[0004]
Further, in the above method for producing an insert molded product, when wear resistance or the like is required on the surface of the insert molded product, a surface protective layer formed by curing an ionizing radiation curable resin on the side in contact with the mold as an insert sheet. What was provided was used.
[0005]
[Problems to be solved by the invention]
However, the conventional method for manufacturing an insert-molded product has the following problems.
[0006]
First, when a surface protective layer obtained by curing an ionizing radiation curable resin is provided on the surface of an insert molded product and a fine uneven pattern is provided on the surface of the surface protective layer, the surface protective layer is hard. There was a problem that it was difficult to accurately shape the surface of the molded product according to the fine irregularities of the mold, and precise design expression could not be achieved. In addition, if the surface protective layer is uncured in the insert molding process, it is possible to accurately shape the mold according to the fine irregularities of the mold, but after removing the insert molded product from the mold, ionizing radiation is irradiated. When the surface protective layer is cured, the surface protective layer contracts, and there is a problem that the fine concavo-convex pattern of the surface protective layer and the design pattern of the decorative layer to be synchronized with the fine concavo-convex pattern are misaligned.
[0007]
Another problem is that the outer shape of the insert molded product is the same and there are a wide variety of fine uneven patterns on the surface, or the outer shape of the insert molded product is the same and only the fine uneven pattern is redesigned. In this case, an injection mold must be made for each fine uneven pattern. However, since an injection mold requires a strong mold clamping force and durability against injection pressure at the time of molding, an expensive steel material must be used, and the resulting insert molded product is expensive.
[0008]
Therefore, an object of the present invention is to solve the above-mentioned problem, and can express a design that gives a precise fine concavo-convex pattern for the surface protective layer on the outermost surface of the insert-molded product, and the fine concavo-convex pattern of the surface protective layer A manufacturing method of an insert sheet having fine unevenness and an insert having fine unevenness, in which no positional deviation occurs between the fine unevenness pattern and the design pattern of the decorative layer to be synchronized, and an insert molded product can be obtained at low cost. A method for producing a molded article is provided.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, the method for producing an insert sheet having a fine relief pattern according to the present invention is provided with at least a surface protective layer made of an uncured ionizing radiation curable resin on one side of a transparent or translucent substrate sheet. The laminated body and a shaping mold having fine irregularities on the surface are arranged so that the surface on the surface protective layer side of the laminated body faces the fine irregularities surface of the shaping mold, and the above-mentioned lamination is performed by heating pressure. The surface of the body surface side of the surface protective layer is shaped by the fine unevenness of the shaping mold, and then the surface protective layer having the fine unevenness pattern is cured by irradiating with ionizing radiation, and further on the base sheet side of the laminate At least a decorative layer having a design pattern that synchronizes with the fine concavo-convex pattern is provided on the surface.
[0010]
Moreover, in the said structure, the fine uneven | corrugated pattern was made into the matte pattern or the hairline pattern which is 0.01-0.5 in height difference.
[0011]
Further, in each of the above-described configurations, ionizing radiation is irradiated before removing the layered product having the surface protective layer formed from the shaping mold.
[0012]
Further, in each of the above-described configurations, the laminate is pre-formed into a three-dimensional shape at the same time as the surface on the surface protective layer side is shaped.
[0013]
The method for producing an insert-molded article having a fine concavo-convex pattern according to the present invention includes disposing an insert sheet obtained by the above-described method in an injection mold having a desired cavity shape, and protecting the surface of the insert sheet after clamping. The resin was injected and filled into the cavity from the side opposite to the layer side and cooled to obtain a resin molded product, and at the same time, the insert sheet was integrated with the surface.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. 1-6 is sectional drawing which shows one Example of the manufacturing method of the insert sheet which has the fine unevenness pattern which concerns on this invention, FIGS. 7-9 is the manufacturing method of the insert sheet molded article which has the fine unevenness pattern which concerns on this invention FIG. 10 to FIG. 12 are sectional views showing an example of a method for shaping the surface protective layer of the laminate according to the present invention, and FIG. 13 is a surface protective layer of the laminate according to the present invention. FIG. 14 is a cross-sectional view showing a method for preforming a laminate while shaping the surface protective layer of the laminate according to the present invention. In the figure, 1 is a substrate sheet, 2 is a surface protective layer, 2a is a fine uneven pattern, 3 is a laminate, 4 is a shaping mold, 4a is fine unevenness, 4b is an upper mold, 4c is a lower mold, 4d is Suction type, 4e is an air inlet, 5 is an ionizing radiation, 6 is a decorative layer, 6a is a design pattern, 7 is an insert sheet, 8 is an insert molded product, 9 is an injection mold, 10 is an adhesive layer, 11 Represents a resin molded product, 12 represents a molten resin, 13 represents a cavity, 14 represents a heater, and 15 represents inflow of compressed air.
[0015]
1 to 6 is a laminate in which a surface protective layer 2 made of an uncured ionizing radiation curable resin is provided on one side of a transparent or translucent substrate sheet 1. 3 (see FIG. 1) and the shaping mold 4 having the fine irregularities 4a on the surface, the surface on the surface protective layer 2 side of the laminate 3 and the fine irregularities 4a of the shaping mold 4 are opposed to each other. (See FIG. 2), the surface of the laminate 3 on the surface protective layer 2 side is shaped by the fine irregularities 4a of the shaping mold 4 by heating pressure (see FIG. 3), and then the ionizing radiation 5 is applied. Irradiation (see FIG. 4) cures the surface protective layer 2 having the fine unevenness pattern 2a, removes the laminate 3 from the shaping mold 4 (see FIG. 5), and further on the base sheet 1 side of the laminate 3 Adhesive layer 10 is provided with a decorative layer 6 having a pattern 6a synchronized with the fine concavo-convex pattern 2a on the surface ( 6 reference) is intended.
[0016]
The transparent or translucent substrate sheet 1 supports the decorative layer 6 and the surface protective layer 2 and enables decoration on a resin molded product having a three-dimensional shape, and the insert sheet 7 depends on its thickness. It gives depth to the decoration by. As the base sheet 1, a PET film, a polycarbonate film, an acrylic film, an olefin film, a polycarbonate / PET mixed film, a single layer film of a urethane film, or a multilayer film in which two or more of these films are laminated is used. be able to. Moreover, the thickness of the base material sheet 1 is good to use the thing of the range of 25 micrometers-250 micrometers. When the thickness is less than 25 μm, it is too thin and handling in the printing or molding process is poor. When the thickness exceeds 250 μm, when the insert sheet 7 is molded into a three-dimensional shape along the inner wall of the injection molding die, the heating time becomes longer due to heat conduction, so the production efficiency is inferior. In addition, when the substrate sheet 1 is wound after the surface protective layer 2 is applied with a material that may cause blocking or the like, the entire surface of the substrate sheet 1 opposite to the surface on which the surface protective layer 2 is provided is provided. In particular, a material having an uneven layer may be used.
[0017]
The surface protective layer 2 is a layer that improves damage resistance, chemical resistance, and the like of the surface of the insert molded product 8. As the surface protective layer 2, an ionizing radiation curable resin, that is, a reactive prepolymer, a polyfunctional oligomer, or a mixture thereof is mixed with a reactive diluent and, if necessary, a photopolymerization initiator is added. Is used. The reactive prepolymer includes a prepolymer having a polymerizable double bond and a prepolymer having an epoxy group, and the multifunctional oligomer includes an oligomer having a polymerizable double bond and an oligomer having an epoxy group. Examples of the prepolymer or oligomer having a polymerizable double bond include (1) an unsaturated polyester composition comprising a polycondensate of an unsaturated dicarboxylic acid or its anhydride and a polyhydric alcohol, and (2) a relatively low molecular weight alkyd. Or an alkyd acrylate or polyester acrylate obtained by condensing acrylic acid to the residual OH group of the polyester, (3) a urethane acrylate obtained by reacting a terminal isocyanate urethane prepolymer obtained by reacting a polyol and a diisocyanate with an acrylate having a hydroxyl group, (4) Silicon acrylate in which acryloyl group is introduced into silicon oligomer, (5) Diene acrylate in which acryloyl group is introduced into the terminal of polybutadiene oligomer, (6) Acrylyl group in melamine oligomer Melamine acrylate, (7) an acryloyl group introduced using a functional group of a side chain of a low molecular weight vinyl copolymer, (8) the acrylic oligomers of (1) to (7) above as an isocyanate compound, There are compositions modified with epoxy compounds, oils and the like. In addition, as a prepolymer or oligomer having an epoxy group, (1) an epoxy acrylate obtained by esterifying acrylic acid to an epoxy resin, and (2) a compound that decomposes by light to generate a Lewis acid is used as a photoinitiator. And a composition for ring-opening polymerization of an epoxy compound. Examples of the reactive diluent include vinyl pyrrolidone, 2-ethylhexyl acrylate, lauryl acrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, tetrahydrofurfuryl acrylate, diethylene glycol diacrylate, tetraethylene glycol diacrylate, and neopentyl glycol diacrylate. , Trimethylolpropane triacrylate, tetramethylolmethane tetraacrylate, and the like can be used. Moreover, a photoinitiator is added as needed. That is, it is added when ultraviolet irradiation is performed, and is not added when electron beam irradiation is performed. Examples of the photopolymerization initiator that can be used include benzoin ethyl ether, benzophenone, benzyl, methyl orthobenzoyl benzoate, chlorothioxanthone, 2,2-diethoxyacetophenone, 2-methylthioxanthone, 2-isopropylthioxanthone, and 1-phenyl-1. -2-propanedione-2- (0-ethoxycarbonyl), 1-phenyl-1, 2-propanedione-2- (0-benzoyl) oxime, etc. The thickness of the surface protective layer 2 is preferably in the range of 1 μm to 20 μm. When the film thickness is less than 1 μm, the function as the surface protective layer 2 is not sufficiently achieved. If the film thickness exceeds 20 μm, the risk of blocking increases immediately after the surface protective layer 2 is formed, and cracks or the like occur when the insert sheet 7 is molded into a three-dimensional shape along the inner wall of the injection mold. It tends to occur and lacks shape followability.
[0018]
In the shaping step, the surface of the laminate 3 on the surface protective layer 2 side is heated and softened so that the surface temperature becomes 100 to 150 ° C., and then a pressing force of 80 bar or more is applied to the fine irregularities of the shaping mold. Is preferably transferred to the surface of the laminate 3 on the surface protective layer 2 side. The surface temperature is the surface temperature immediately before shaping of the heated laminate 3, that is, the surface temperature when the laminate moves from the heating zone to the shaping zone in the examples of FIGS. The heating conditions of the heater 14 and the like are adjusted so that a temperature label is applied to the laminate 3 so as to be in an appropriate temperature region. When the surface temperature is less than 100 ° C., the heat unevenness is insufficient, so that the fine irregularities 4a of the shaping mold 4 are not transferred. When the surface temperature exceeds 150 ° C., it becomes too soft and it becomes difficult to remove the mold. In addition, when the load is less than 80 bar, it is difficult to accurately shape the fine unevenness 4a of the shaping die 4. Instead of pressing the laminate 3 against the shaping die 4 as shown in FIGS. 10 to 12, the shaping die 4 may be pressed against the laminate 3 (not shown). Moreover, when the fine unevenness | corrugation 4a of the shaping | molding type | mold 4 is deep with respect to the film thickness of the surface protective layer 2, shaping | molding may reach not only the surface protective layer 2 but the base material sheet 1 under it. . 10 to 12 is an example, and includes an upper mold 4b having an air inlet e and a lower mold 4c having a suction mold 4d having fine irregularities 4a. It is heated by the compressed air inflow 15.
[0019]
The fine concavo-convex pattern 2a of the surface protective layer 2 is, for example, a matte pattern or a hairline pattern having a height difference of 0.01 mm or more and less than 0.5, and is finely formed on the shaping mold 4 so that it can be shaped. The unevenness 4a is partially provided. When the outer shape of the insert molded product 8 is the same and there are a wide variety of fine uneven patterns 2a on the surface, or when the outer shape of the insert molded product 8 is the same and the fine uneven pattern 2a of the surface protective layer 2 is redesigned In this case, the shaping mold 4 is made for each fine concavo-convex pattern 2a. However, since the shaping mold 4 does not require a strong clamping force or durability against injection pressure, an inexpensive material, for example, Resin material such as aluminum material, brass material, acrylic resin, polycarbonate resin, etc. can be used, and it is less expensive than the case where fine irregularities are provided on the injection mold. As a means for forming the fine irregularities 4a on the shaping mold 4, in the case of the shaping mold 4 made of aluminum or brass, an etching method, a sand blasting method, an electrode electric discharge machining method, an NC machining method, or the like is used. In the case of the shaping mold 4 to be formed, a sandblasting method, an NC processing method or the like can be used. Further, the shaping mold 4 may be a mold member in which a part of the mold member is nested and the mold member whose surface is polished is inserted.
[0020]
As the ionizing radiation 5 for curing the surface protective layer 2, ultraviolet rays are used, and 400 to 4000 mJ / cm. ² It is good to irradiate under the condition of the degree. As described above, when the ionizing radiation 5 is irradiated in a state where the surface of the laminate 3 on the surface protective layer 2 side is shaped by the fine irregularities 4a of the shaping mold 4, the irradiation of the ionizing radiation 5 is basically based on the above. Although it is performed via the material sheet 1 (see FIG. 4), when the shaping mold 4 is made of a transparent resin, it can also be carried out via the shaping mold 4 (not shown). Irradiation with ionizing radiation 5 is performed after the surface of the laminate 3 on the surface protective layer 2 side is shaped by the fine irregularities 4 a of the shaping mold 4 and the laminate 3 is removed from the shaping mold 4. (See FIG. 13).
[0021]
The decorative layer 6 is for decorating a resin molded product, and has a pattern 6a that synchronizes with the fine concavo-convex pattern 2a of the surface protective layer 2. Further, the decorative layer 6 may have a design pattern that does not synchronize with the fine concavo-convex pattern 2 a of the surface protective layer 2, in addition to the design pattern 6 a that synchronizes with the fine concavo-convex pattern 2 a of the surface protective layer 2. The decoration layer 6 is usually formed as a printing layer. As a material of the decorative layer 6 made of a printing layer, polyvinyl chloride resin, polyamide resin, polyester resin, polyacrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin A colored ink containing a resin such as an alkyd resin as a binder and a pigment or dye of an appropriate color as a colorant may be used. As a method for forming the decorative layer 6 made of a 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. In the case of a single color, a coating method such as a gravure coating method, a roll coating method, or a comma coating method may be employed. The print layer may be provided entirely or partially depending on the pattern to be expressed. The thickness of the print layer is preferably in the range of 1 to 30 μm. When the film thickness is less than 1 μm, it becomes difficult to exhibit sufficient fixing force in interlayer adhesion with other layers. When the film thickness exceeds 30 μm, the residual solvent is unlikely to volatilize, so that the ink flow tends to occur in the insert process.
[0022]
Moreover, the decoration layer 6 may consist of only a metal thin film layer or 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 decorative layer 6 and is formed by a vacuum deposition method, a sputtering method, an ion plating method or the like. In this case, a metal such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, or zinc, or an alloy or compound thereof is 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. A solvent often used in this case is water or an aqueous solution. As another example, a method of removing a resist layer by forming a metal thin film on the entire surface, then forming a resist layer on a portion where the metal thin film is to be left, etching with acid or alkali, There is a method of forming a metal thin film on the entire surface and removing an unnecessary metal thin film with a laser beam. The film thickness of the metal thin film layer as the decoration layer is generally 10 nm or more. This is because when the film thickness is less than 10 nm, it is difficult to control the film thickness in the vapor deposition process.
[0023]
The adhesive layer 10 is a layer for adhering the insert sheet 7 to the resin molded product 11. The adhesive layer 10 is appropriately selected according to the material of the resin molded product 11 to be integrated. For example, when the material of the resin molded product 11 is a polyacrylic resin, a polyacrylic resin may be used. Further, when the material of the resin molded product 11 is polyphenylene oxide / polystyrene resin, polycarbonate resin, styrene copolymer resin, or polystyrene blend resin, polyacrylic resin or polystyrene resin having an affinity for these resins Polyamide resin, vinyl chloride resin, etc. may be used. Furthermore, when the material of the resin molded product 11 is polypropylene resin, polypropylene chloride resin, ethylene vinyl acetate resin chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, coumarone indene resin are used. It can be used. When the material of the resin molded article 11 is bonded to a thermosetting plastic resin such as silicone rubber, an organic solvent solution of a titanate ester, a carbon functional silane, or a mixture thereof, a polyurethane resin, a polyester resin, An ethylene-vinyl acetate copolymer resin, a polyvinyl chloride resin, an acrylic resin, a butyral resin, an acetal resin, or a resin obtained by adding alkoxysilane, chlorosilane, or the like as a silane compound can be used. The adhesive layer 10 may be colored or uncolored. Moreover, even when coloring, it may be transparent or translucent. Examples of the method for forming the adhesive layer 10 include a printing method such as a gravure printing method and a screen printing method, and a coating method such as a gravure coating method, a roll coating method, and a spray coating method. The dry film thickness of the adhesive layer is generally 1-30 μm. When the film thickness is less than 1 μm, sufficient adhesion with the resin molded product cannot be obtained. When the film thickness exceeds 30 μm, it is difficult to form by each printing method.
[0024]
In addition, the structure of the insert sheet 7 which concerns on this invention is not limited to the aspect shown in the said FIGS. 1-6, For example, as a material of the decorating layer 6 or the base material sheet 1, resin-molded goods and 11 In the case of using a material having excellent adhesive layer properties, the adhesive layer 10 can be omitted (not shown).
[0025]
Moreover, when providing a metal thin film layer, in order to improve the adhesiveness of another layer and a metal thin film layer, it is good to provide an anchor layer before and behind a metal thin film layer (not shown). The material of the anchor layer is preferably selected from thermosetting resins. The reason is that since it is excellent in heat resistance and flexibility, the metallic luster is not impaired without causing fine cracks in the anchor layer. In particular, an acrylic polyol-based thermosetting resin is more preferable because it is excellent in transparency and can reproduce the glossiness of a metal design. Moreover, in order to improve the adhesiveness of the base material sheet 1 and the surface protective layer 2, you may provide an anchor layer (not shown). Examples of the method for forming the anchor layer include a coating method such as a gravure coating method and a roll coating method, a printing method such as a gravure coating method and a screen printing method. The thickness of the anchor layer is generally 0.1 to 5 μm. When the film thickness is less than 0.1 μm, it is difficult to form by each printing method. When the film thickness exceeds 5 μm, the fixation becomes unstable due to variation in curing.
[0026]
In addition, when it is necessary to preform the insert sheet 7 into a three-dimensional shape before injection molding, the laminate 3 is preformed into a three-dimensional shape at the same time as the surface on the surface protective layer 2 side is shaped. (See FIG. 14). As the preforming method, any one of a high pressure forming method, a hydraulic forming method, a pressure forming method, a vacuum forming method, and a pressure vacuum forming method may be used. In addition, when the surface of the surface protective layer 2 side is shaped in this way and at the same time the laminate 3 is preformed into a three-dimensional shape, the surface of the base sheet 1 provided with the surface protective layer 2 having the fine unevenness pattern 2a; As a means for forming the decorative layer 6 on the opposite surface, a hot stamp method or pad printing is used.
[0027]
Next, the surface protection layer 2 obtained as described above is integrated with the surface of the resin molded product 11 using the insert sheet 7 having the fine concavo-convex pattern 2a to produce the insert molded product 8 having the fine concavo-convex pattern. How to do will be described.
[0028]
First, the insert sheet 7 having the fine concavo-convex pattern 2a is fed into an injection mold 9 which is composed of a movable mold and a fixed mold and has a desired cavity shape (see FIG. 7). At this time, the sheet-like insert sheets 7 may be fed one by one, or necessary portions of the long insert sheet may be intermittently fed. When the long insert sheet 7 is used, a register having a positioning mechanism is used, and the registration of the fine unevenness pattern 2a of the insert sheet 7 or the pattern of the decorative layer 6 and the injection mold 9 coincides. It is good to do so. Further, when the insert sheet 7 is intermittently fed, if the insert sheet 7 is fixed by the movable mold and the fixed mold after the position of the insert sheet 7 is detected by the sensor, the insert sheet 7 is always at the same position. It is convenient because the positional deviation of the fine uneven pattern 2a and the pattern of the decorative layer 6 does not occur. After clamping, the molten resin 12 is injected and filled into the cavity 13 from the side opposite to the surface protective layer 2 side of the insert sheet 7 (see FIG. 8) and cooled to obtain the resin molded product 11 at the same time. The insert sheet 7 is integrated. Thereafter, the mold is opened and the insert molded product 8 is taken out (see FIG. 9).
[0029]
Examples of the material of the resin molded product 11 include general-purpose resins such as polystyrene resin, polyolefin resin, ABS resin, AS resin, and AN resin. Also, general engineering resins such as polyphenylene oxide / polystyrene resins, polycarbonate resins, polyacetal resins, polyacrylic resins, polycarbonate-modified polyphenylene ether resins, polybutylene terephthalate resins, ultrahigh molecular weight polyethylene resins, polysulfone resins, polyphenylene sulfide Super engineering resins such as resins, polyphenylene oxide resins, polyarylate resins, polyetherimide resins, polyimide resins, liquid crystal polyester resins, and polyallyl heat-resistant resins can also be used. Furthermore, composite resins to which reinforcing materials such as glass fibers and inorganic fillers are added can also be used. These may be transparent, translucent, or opaque. Moreover, the resin molded product 11 may be colored or may not be colored.
[0030]
【Example】
(Example 1) A PC film having a thickness of 130 μm is used as a base sheet, and a surface protective layer made of urethane acrylate resin is formed on one side thereof with a film thickness of 5 μm by a reverse coating method to obtain a laminate, which has a desired size (240 × 310 mm). Thereafter, the laminate is disposed so that the surface on the surface protective layer side and the fine irregular surface are opposed to a shaping mold made of an aluminum member having fine irregularities partially formed on the surface, and the laminate After heating with a far-infrared heater so that the surface temperature of the laminate becomes 130 ° C., a pressure of 120 bar is applied to the laminate, so that the surface on the surface protective layer side of the laminate is formed by fine irregularities of the shaping mold Shaped. 2000 mJ / cm in that state ² After the surface protective layer was cured by irradiating the surface protective layer with UV rays of the above through the base sheet, the mold was removed from the shaping mold. Next, the sheet is further cut, and on the surface opposite to the surface provided with the surface protective layer having the fine uneven pattern of the base sheet, “SG410 / dedicated curing agent = 10: 1” (urethane two-liquid curing type) manufactured by Seiko Advance A decorative layer having a pattern that synchronizes with the fine concavo-convex pattern was formed by screen printing using Sumi ink, and hot air drying was applied at 80 ° C. for 5 minutes. Finally, an adhesive layer made of vinyl chloride-vinyl acetate copolymer resin is formed on the entire surface by screen printing, and finally dried at 80 ° C. for 2 hours to form a fine uneven pattern that is a matte pattern with a height difference of 0.1 mm. An insert sheet was obtained.
[0031]
The insert sheet having the fine concavo-convex pattern obtained as described above is cut into a final product size, and the insert sheet is heated to a surface temperature of 130 ° C. by a high pressure molding method, and then preformed at a pressure of 120 bar. The solid shape corresponds to the cavity shape of the injection mold. Next, an insert sheet preliminarily molded into a three-dimensional shape corresponding to the cavity shape of the injection mold and having a fine uneven pattern on the surface on the surface protective layer side is placed in the mold, and Bayer PC resin “Macrolon” 2205 "was melted, injected, and cooled and solidified to obtain an insert molded product in which an insert sheet having a fine concavo-convex pattern was integrated on the surface.
[0032]
(Example 2) A urethane film having a thickness of 150 μm was used as a base sheet, and a surface protective layer made of urethane acrylate resin was formed on one side thereof with a film thickness of 5 μm by a reverse coating method to obtain a laminate, which had a desired size (310 × 410 mm). Thereafter, the laminate is disposed so that the surface on the surface protective layer side and the fine irregular surface are opposed to a shaping mold made of a brass material with fine irregularities partially formed on the surface, and the laminate After heating with a far-infrared heater so that the surface temperature of the laminate becomes 130 ° C., a pressure of 120 bar is applied to the laminate, so that the surface on the surface protective layer side of the laminate is formed by fine irregularities of the shaping mold Shaped. After removing the laminate from the shaping mold, 2000 mJ / cm ² The surface protective layer was cured by directly irradiating the surface protective layer with UV rays of no through the base sheet.
Next, the sheet is further cut, and on the surface opposite to the surface provided with the surface protective layer having the fine uneven pattern of the base sheet, “SG410 / dedicated curing agent = 10: 1” (urethane two-liquid curing type) manufactured by Seiko Advance Sumi ink) is used to form a decorative layer with a pattern that synchronizes with the fine concavo-convex pattern by screen printing, and hot air drying is performed at 80 ° C. for 5 minutes, and the fine concavo-convex pattern is a matte pattern with a height difference of 0.1 mm. An insert sheet having a pattern was obtained.
[0033]
The insert sheet having the fine concavo-convex pattern obtained as described above is cut into a final product size, and the insert sheet is heated to a surface temperature of 130 ° C. by a high pressure molding method, and then preformed at a pressure of 120 bar. The solid shape corresponds to the cavity shape of the injection mold. Next, an insert sheet preliminarily molded into a three-dimensional shape corresponding to the cavity shape of the injection mold and having a fine uneven pattern on the surface on the surface protective layer side is placed in the mold, and Bayer PC resin “Macrolon” 2205 "was melted, injected, and cooled and solidified to obtain an insert molded product in which an insert sheet having a fine concavo-convex pattern was integrated on the surface.
[0034]
(Example 3) As a shaping mold, a recess having a cavity shape corresponding to the cavity shape of an injection molding mold was used. Example 1 was the same as Example 1 except that it was carried out at the same time as the shaping of the laminate rather than after the production, and that pad printing was used as the means for forming the decorative layer.
[0035]
(Example 4) As a shaping mold, a concave portion corresponding to the cavity shape of an injection mold is used, and a surface having fine irregularities partially formed on the surface of the concave portion is used as an insert sheet. Example 2 was the same as Example 2 except that the laminated body was shaped and preformed at the same time, and pad printing was used as the decorative layer forming means.
[0036]
【The invention's effect】
Since the method for producing an insert sheet having a fine uneven pattern and the method for producing an insert molded product having a fine uneven pattern according to the present invention have the above-described configuration, the following excellent effects are exhibited.
[0037]
That is, the insert sheet manufacturing process includes a laminate having at least a surface protective layer made of an uncured ionizing radiation curable resin on one side of a transparent or translucent substrate sheet and a shaping mold having fine irregularities on the surface. And the surface on the surface protective layer side of the laminate and the fine irregular surface of the shaping mold face each other, and the surface on the surface protective layer side of the laminate is heated by the pressure of the shaping mold Because it is shaped by fine irregularities, and then the surface protection layer with fine irregularities is cured by irradiating with ionizing radiation, the insert sheet is precisely shaped according to the fine irregularities of the shaping mold It will be an expression.
[0038]
Furthermore, since the manufacturing process of the insert sheet is provided with a decorative layer having a design pattern that synchronizes with the fine concavo-convex pattern on the surface on the base sheet side of the laminate after the above shaping, the surface protective layer by irradiation with ionizing radiation is provided. Even if the shrinkage occurs, the fine uneven pattern of the surface protective layer and the design pattern of the decorative layer to be synchronized with the fine uneven pattern are not misaligned.
[0039]
Also, when the outer shape of the insert molded product is the same and there are a wide variety of fine uneven patterns on the surface, or when the outer shape of the insert molded product is the same and only the fine uneven pattern of the surface protective layer is redesigned However, since the mold for shaping is made for each fine concavo-convex pattern, the above-mentioned shaping mold does not require a strong clamping force or durability against injection pressure, so it can be used with inexpensive materials and injection molding. Compared with the case where fine irregularities are provided on the metal mold, the cost is low.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a method for producing an insert sheet having a fine concavo-convex pattern according to the present invention.
FIG. 2 is a cross-sectional view showing an embodiment of a method for producing an insert sheet having a fine concavo-convex pattern according to the present invention.
FIG. 3 is a cross-sectional view showing an embodiment of a method for producing an insert sheet having a fine concavo-convex pattern according to the present invention.
FIG. 4 is a cross-sectional view showing an embodiment of a method for producing an insert sheet having a fine concavo-convex pattern according to the present invention.
FIG. 5 is a cross-sectional view showing an embodiment of a method for producing an insert sheet having a fine concavo-convex pattern according to the present invention.
FIG. 6 is a cross-sectional view showing an embodiment of a method for producing an insert sheet having a fine concavo-convex pattern according to the present invention.
FIG. 7 is a cross-sectional view showing one embodiment of a method for producing an insert sheet molded article having a fine unevenness pattern according to the present invention.
FIG. 8 is a cross-sectional view showing one embodiment of a method for producing an insert sheet molded article having a fine uneven pattern according to the present invention.
FIG. 9 is a cross-sectional view showing an embodiment of a method for producing an insert sheet molded article having a fine uneven pattern according to the present invention.
FIG. 10 is a cross-sectional view showing an example of a method for shaping a surface protective layer of a laminate according to the present invention.
FIG. 11 is a cross-sectional view showing an example of a method for shaping a surface protective layer of a laminate according to the present invention.
FIG. 12 is a cross-sectional view showing an example of a method for shaping a surface protective layer of a laminate according to the present invention.
FIG. 13 is a cross-sectional view showing a variation of the method for curing the surface protective layer of the laminate according to the present invention.
FIG. 14 is a cross-sectional view showing a method of shaping a surface protective layer of a laminate according to the present invention and preforming the laminate.
FIG. 15 is a cross-sectional view showing a method of manufacturing an insert sheet molded article having a fine uneven pattern according to the prior art.
FIG. 16 is a cross-sectional view showing a method for manufacturing an insert sheet molded article having a fine uneven pattern according to the prior art.
[Explanation of symbols]
1 Base sheet
2 Surface protective layer
2a Fine uneven pattern
3 Laminate
4 Mold for shaping
4a Fine irregularities
4b Upper mold
4c Lower mold
4d suction type
4e Air inlet,
5 ionizing radiation
6 decoration layer
6a design
7 Insert sheet
8 Insert molded products
9 Injection mold
9a Fine irregularities
10 Adhesive layer
11 resin molded products
12 Molten resin
13 cavity
14 Heater
15 Pressure air inflow

Claims (5)

Surface protection of a laminate using a laminate having at least a surface protective layer made of an uncured ionizing radiation curable resin on one side of a transparent or translucent substrate sheet and a shaping mold having fine irregularities on the surface The surface on the layer side and the fine uneven surface of the shaping mold are arranged so as to face each other, and the surface on the surface protective layer side of the laminate is shaped by the fine unevenness of the shaping mold by heating pressure, and then The surface protective layer having a fine uneven pattern is cured by irradiating with ionizing radiation, and at least a decorative layer having a design pattern synchronized with the fine uneven pattern is provided on the base sheet side surface of the laminate. The manufacturing method of the insert sheet which has a fine uneven | corrugated pattern to do. The method for producing an insert sheet having a fine concavo-convex pattern according to claim 1, wherein the fine concavo-convex pattern is a matte pattern or a hairline pattern having a height difference of 0.01 mm or more and less than 0.5. The method for producing an insert sheet having a fine concavo-convex pattern according to any one of claims 1 and 2, wherein irradiation of ionizing radiation is performed before removing the laminate having the surface protective layer formed from the shaping mold. . The manufacturing method of the insert sheet which has a fine unevenness | corrugation pattern in any one of Claims 1-3 which shape | molds the said laminated body on the surface by the side of the surface protective layer simultaneously with pre-molding in the solid | 3D shape. The insert sheet obtained by the method of claims 1 to 4 is placed in an injection mold having a desired cavity shape, and after clamping, a resin is inserted into the cavity from the side opposite to the surface protective layer side of the insert sheet. A process for producing an insert-molded article having a fine concavo-convex pattern, characterized in that the resin sheet is obtained by injection filling and cooling, and at the same time an insert sheet is integrated on the surface thereof.

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