JP4054455B2 - Simultaneous molding material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
This invention prevents a foil burr generated from a transfer material from sticking to a mold during continuous molding when decorating the surface of a resin molded product used for home appliances, cosmetic containers, miscellaneous goods, etc., by a simultaneous molding method. The present invention relates to a molding simultaneous transfer material that can be used.
[0002]
[Prior art]
As a method for decorating the surface of a resin molded product, there is a simultaneous molding transfer method. The simultaneous molding transfer method is a method in which a transfer material in which a transfer layer composed of a release layer, a design layer, an adhesive layer, etc. is formed on a base sheet is sandwiched in a molding die, resin is injected into the die, and cooled. In this method, a transfer material is adhered to the surface of the molded product at the same time as the resin molded product is obtained, and then the base sheet is peeled off, and the transfer layer is transferred to the surface of the transfer object to decorate.
[0003]
In the simultaneous molding and transfer method, there is a problem that foil burrs generated from the transfer material adhere to the mold during continuous molding. That is, in the non-transfer part of the transfer layer provided larger than the transfer area of the transfer object, particularly in the non-transfer part of the transfer layer provided so as to close the hole when the transfer object has a shape with a hole, After the base sheet is peeled off, so-called foil burrs are generated in which the transfer layer remains attached around the molded product and in the holes. The foil burr is dropped from the molded product by an impact when the mold is opened, and adheres to the core mold side of the mold by the action of static electricity. Thereafter, when the mold is clamped to perform the next molding, the foil burrs adhering to the portion sandwiched between the cavity mold and the core mold are fixed to the cavity mold or the core mold by the mold clamping pressure. It should be noted that the foil burrs that were not sandwiched between the molds when the molds were clamped fall off from the molds due to the impact when the molds are opened and closed.
[0004]
In order to prevent foil burrs from sticking to the mold, there are methods to make the foil burrs difficult to adhere to the mold from the beginning by applying Teflon processing to the mold or polishing the mold surface to a mirror surface. is there. Adhesive tape is applied to the location where foil burrs occur, creating a minute gap between the cavity surface and the core surface, and by applying no pressure to the area where the foil burrs are attached during mold clamping, There is a method to prevent sticking to the mold. Further, there is a method for preventing the sticking of the foil burr to the mold by lowering the mold temperature at the time of molding. In addition, there is a method for preventing sticking of the foil burr to the mold by lowering the clamping pressure at the time of molding.
[0005]
[Problems to be solved by the invention]
However, performing Teflon processing on the mold or polishing the mold surface to a mirror surface is expensive in processing cost and lacks durability of Teflon processing and mirror surface treatment. Moreover, sticking an adhesive tape to a place where foil burrs are generated is complicated and the production efficiency is remarkably reduced. In addition, when the mold temperature is lowered at the time of molding, the adhesion between the transfer layer of the transfer material and the molding resin may decrease, or the adhesion between the layers constituting the transfer layer may decrease, causing peeling. . Moreover, if the clamping pressure at the time of molding is lowered, resin burrs may be generated.
[0006]
Accordingly, an object of the present invention is to provide a molding simultaneous transfer material that can eliminate the above-described problems and prevent the foil burrs generated from the transfer material from sticking to the mold during continuous molding. To do.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, the molding simultaneous transfer material of the present invention is configured as follows.
[0008]
[Means for Solving the Problems]
That is, the molding simultaneous transfer material of the present invention is a non-transfer portion sandwiched between molds in a transfer material in which a transfer layer is formed on a peelable substrate sheet, rather than the thickness of the transfer layer of the transfer portion in contact with the molding resin. the thickness of the transfer layer is rather large, the transfer layer non-transfer portion or not peeled from the base sheet, or is constructed as a small release properties than the peeling of the transfer layer of the transfer portion.
[0009]
In the above invention, the thickness of the transfer layer in the non-transfer portion may be 0.1 to 300 μm larger than the thickness of the transfer layer in the transfer portion.
[0010]
In the above invention, the transfer layer of the non-transfer portion may be formed of any one of a release layer, a design layer, an anchor layer, and an adhesive layer.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described in detail with reference to the drawings.
[0013]
FIG. 1 is a cross-sectional view showing one embodiment of the simultaneous molding and transfer material of the present invention. FIG. 2 is a cross-sectional view showing a state where simultaneous molding transfer is performed using the simultaneous molding transfer material of the present invention. FIG. 3 is a cross-sectional view showing a molded product obtained using the molding simultaneous transfer material of the present invention. In the figure, 1 is a molding simultaneous transfer material, 2 is a base sheet, 3 is a release layer, 4 is a design layer, 5 is an adhesive layer, 6 is a transfer layer, 7 is a cavity mold, 8 is a core mold, and 9 is a molding resin. is there.
[0014]
The molding simultaneous transfer material 1 according to the present invention is sandwiched between molds in a transfer material in which a transfer layer 6 is formed on a base sheet 2 having releasability, rather than the thickness of the transfer layer 6 at the transfer portion in contact with the molding resin 9. The thickness of the transfer layer 6 in the non-transfer portion is large (see FIG. 1).
[0015]
The molding simultaneous transfer material 1 is obtained by forming a transfer layer 6 including a release layer 3, a design layer 4, and an adhesive layer 5 on a base sheet 2.
[0016]
The material of the base sheet 2 includes polypropylene resin, polyethylene resin, polyamide resin, polyester resin, acrylic resin, polyvinyl chloride resin resin sheet, aluminum foil, copper foil and other metal foil, glassine paper In addition, a cellulose-based sheet such as coated paper or cellophane, or a composite of each of the above-described sheets can be used as a base sheet 2 for a normal transfer material. Moreover, when the surface of the base sheet 2 has fine irregularities, the irregularities are copied onto the transfer layer 6, and a surface shape such as matte or hairline can be expressed.
[0017]
When the peelability of the transfer layer 6 from the base sheet 2 is good, the transfer layer 6 may be provided directly on the base sheet 2. In order to improve the peelability of the transfer layer 6 from the base sheet 2, the release layer may be formed on the entire surface before the transfer layer 6 is provided on the base sheet 2. The release layer is released from the transfer layer 6 together with the base sheet 2 when the base sheet 2 is peeled off after simultaneous molding and 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.
[0018]
The release layer 3 is formed entirely or partially on the base sheet 2 or the release layer. In order to prevent foil burrs from occurring in the non-transfer portion, it is preferable to provide the release layer 3 only in the transfer portion. However, in order to provide the release layer 3 partially, it is necessary to accurately register. Is difficult. The release layer 3 is a layer that peels from the base sheet 2 or the release layer and becomes the outermost surface of the transfer object when the base sheet 2 is peeled off after simultaneous molding and transfer. The release layer 3 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. Copolymers such as system resins and ethylene-vinyl acetate copolymer resins may be used. When the release layer 3 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 3 may be colored or uncolored. Examples of the method for forming the release layer 3 include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.
[0019]
The design layer 4 is usually formed on the release layer 3 as a printing layer. As a material for the printing layer, a resin such as polyvinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, alkyd resin is used as a binder. A colored ink containing a pigment or dye of an appropriate color as a colorant may be used. When it is desired to obtain a metal color, metal powder or the like may be used as a pigment. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, a screen printing method, or a coating method such as a gravure coating method, a roll coating method, or a comma coating method may be employed. The printed layer is preferably formed to a thickness of 0.5 to 50 μm. The print layer may be provided entirely or partially depending on the pattern to be expressed.
[0020]
The design layer 4 may be composed of 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 metallic luster as the pattern layer 4 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. Moreover, when providing a metal thin film layer, in order to improve the adhesiveness of the other transfer layer 6 and a metal thin film layer, you may provide a front anchor layer and a back anchor layer. As materials for the front anchor layer and the rear anchor layer, two-component cured urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, acrylic resin, epoxy It is preferable to use a vinyl resin, a vinyl copolymer resin, or the like. Examples of methods for forming the front anchor layer and the rear anchor layer include coating methods such as gravure coating, roll coating, and comma coating, printing methods such as gravure printing, and screen printing.
[0021]
The adhesive layer 5 adheres each of the above layers to the surface of the transfer object. The adhesive layer 5 is formed entirely or partially. As the adhesive layer 5, a heat-sensitive or pressure-sensitive resin suitable for the material of the transfer object is appropriately used. For example, when the material of the transfer object is an acrylic resin, an acrylic resin may be used. In addition, when the material of the material to be transferred 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. Further, when the material of the transfer object 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 5 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.
[0022]
The configuration of the transfer layer 6 is not limited to the above-described embodiment. For example, when the material of the design layer 4 that has excellent adhesion to the transfer object is used, the adhesive layer 5 is omitted. be able to.
[0023]
In the transfer material having such a layer structure, the thickness of the transfer layer 6 in the non-transfer portion sandwiched between the molds is larger than the thickness of the transfer layer 6 in the transfer portion in contact with the molding resin 9. That is, when the mold is closed, the gap between the core mold 8 and the cavity mold 7 is generated by the difference between the thickness of the transfer layer 6 in the non-transfer portion and the thickness of the transfer layer 6 in the transfer portion. Can be prevented from being pressed against the mold by the clamping pressure, so that it is possible to prevent the foil burr from sticking to the mold.
[0024]
The thickness of the transfer layer 6 in the non-transfer portion is preferably 0.1 to 300 μm larger than the thickness of the transfer layer 6 in the transfer portion. When the thickness of the transfer layer 6 in the non-transfer portion is less than 0.1 μm than the transfer portion, the foil burrs that are generated are pressed against and fixed by the mold when the mold is closed. . Moreover, when exceeding 300 micrometers, it may cause a resin burr | flash.
[0025]
In order to increase the thickness of the transfer layer 6 in the non-transfer portion, it is intended to increase the thickness of the transfer layer 6, such as a dummy pattern layer 4 or an anchor layer that is not intended to exhibit other effects. The transfer layer 6 is preferably laminated on the non-transfer portion. Further, when the transfer layer 6 that does not peel from the base sheet 2 or has a peelability smaller than the peelability of the transfer portion is formed in the non-transfer portion, the generation of foil burrs can be further suppressed.
[0026]
A method for decorating the surface of a resin molded product, which is a transfer object, using the transfer material having the above-described layer structure and utilizing a simultaneous molding transfer method by injection molding will be described.
[0027]
First, the molding simultaneous transfer material 1 is fed into a molding die composed of the cavity mold 7 and the core mold 8 and positioned and fixed. At that time, the single sheet simultaneous molding transfer material 1 may be fed one by one, or a necessary part of the long molding simultaneous transfer material 1 may be intermittently fed.
[0028]
Next, the molding die is closed, and the molding simultaneous transfer material 1 is sandwiched between the molds (see FIG. 2). The molding simultaneous transfer material 1 has a cavity mold 7 and a core mold 8 formed by increasing the thickness of the transfer layer 6 in the non-transfer portion sandwiched between the molds more than the thickness of the transfer layer 6 in the transfer portion in contact with the molding resin 9. A gap to the extent that no resin burrs are generated between them can be provided to permanently prevent sticking of the foil burrs to the mold. That is, even if a foil burr occurs, a gap is provided so that a resin burr is not generated, so that a mold clamping pressure is applied to the foil burr sandwiched between the cavity mold 7 and the core mold 8 even when the mold is closed. The foil burr is not pressed down by the mold because it is not applied or is very low even when pressure is applied, and the foil burr does not adhere to the mold.
[0029]
Since the transfer layer 6 of the non-transfer portion is thicker than the transfer layer 6 of the transfer portion, a clamping pressure is applied to the non-transfer portion, and the transfer layer 6 of the non-transfer portion is strongly pressed against the mold. The transfer layer 6 in the non-transfer portion is not peeled off from the base sheet 2 or is configured to be difficult to peel off from the base sheet 2 so that the transfer layer 6 in the non-transfer portion is in close contact with the base sheet 2. In addition, the foil burr can be prevented from being fixed to the mold.
[0030]
Next, the molding resin 9 is injected and filled into the mold from the gate provided in the core mold 8, and simultaneously with the formation of the transfer object, the molding simultaneous transfer material 1 is adhered to the surface (see FIG. 2).
[0031]
Examples of the molding resin 9 include general-purpose resins such as polystyrene resin, polyolefin resin, ABS resin, and AS resin. Also, general-purpose engineering resins and polysulfone resins such as polyphenylene oxide / polystyrene resins, polycarbonate resins, polyacetal resins, acrylic resins, polycarbonate-modified polyphenylene ether resins, polybutylene terephthalate resins, polybutylene terephthalate resins, and ultrahigh molecular weight polyethylene resins. Super engineering resins such as polyphenylene sulfide 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.
[0032]
After the resin molded product, which is the transfer target, is cooled, the molding die is opened and the resin molded product is taken out. Finally, the transfer is completed by peeling off the base sheet 2 (see FIG. 3).
[0033]
The molding simultaneous transfer method is not limited to the injection molding method, but also the compression molding method, transfer molding method, laminate molding method, cast molding method, slash molding method, dip molding method, extrusion molding method, inflation molding method, blow molding method. It can also be applied to the method and vacuum forming method.
[0034]
【Example】
A polyethylene terephthalate film having a thickness of 50 μm is used as a base sheet, a release layer is formed thereon using an active energy ray-curable resin ink, a pattern layer is formed using an acrylic resin-based ink, and vinyl chloride / vinyl acetate is used. An adhesive layer was formed using a polymer resin ink. The pattern layer was provided so that the thickness of the transfer layer in the non-transfer portion sandwiched between the molds was 5 μm larger than the thickness of the transfer layer in the transfer portion in contact with the molding resin. Thus, a molding simultaneous transfer material for a front panel of a mobile phone was obtained.
[0035]
The molding simultaneous transfer material obtained in this way is placed in an injection mold and clamped. After injection of acrylonitrile butadiene styrene resin as the molding resin, the mold is opened to obtain a molded product and transferred simultaneously. Went. The molding conditions used were J220SAII manufactured by Nippon Steel Works as an injection molding machine, movable mold temperature 60 ° C, fixed mold temperature 60 ° C, clamping force 130t, heater temperature H1 = 210 ° C, H2 = 215 ° C, H3 = 220. C., H4 = 220.degree. C., NH = 220.degree. C., injection time 0.85 seconds, cooling time 20 seconds, injection pressure holding time 2 seconds. When simultaneous molding and transfer were performed 200 times continuously, no sticking of foil burrs to the mold was observed.
[0036]
As a comparative example, molding simultaneous transfer was performed under the same conditions using a molding simultaneous transfer material having the same configuration as in the above example except that the thickness of the transfer layer was uniform. After the fifth molding, the foil burrs were applied to the mold. Stuck.
[0037]
【The invention's effect】
Since this invention consists of an above-described structure, it has the following effects.
[0038]
The molding simultaneous transfer material of the present invention is a transfer material in which a transfer layer is formed on a peelable substrate sheet. Transfer of a non-transfer portion sandwiched between molds rather than the thickness of the transfer layer of the transfer portion in contact with the molding resin Since the thickness of the layer is large, a certain distance is generated between the cavity mold and the core mold, and the generated foil burr is molded without being pressed against the mold by the pressure at the time of clamping. The foil burrs generated from the transfer material during continuous molding can be prevented from adhering to the mold under optimum molding conditions without any processing on the mold.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a simultaneous molding and transfer material of the present invention.
FIG. 2 is a cross-sectional view showing a state in which simultaneous molding transfer is performed using the simultaneous molding transfer material of the present invention.
FIG. 3 is a cross-sectional view showing a molded product obtained using the molding simultaneous transfer material of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Molding simultaneous transfer material 2 Base sheet 3 Release layer 4 Design layer 5 Adhesive layer 6 Transfer layer 7 Cavity mold 8 Core mold 9 Molding resin

Claims (3)

In the transfer material transfer layer is formed on a substrate sheet having release properties, the thickness of the transfer layer non-transfer portion sandwiched in the mold than the thickness of the transfer layer of the transfer portion in contact with the molding resin is rather large, non-transferable A molding simultaneous transfer material, wherein the transfer layer of the part does not peel from the substrate sheet, or the peelability is lower than the peelability of the transfer layer of the transfer part .   The molding simultaneous transfer material according to claim 1, wherein the thickness of the transfer layer in the non-transfer portion is 0.1 to 300 µm larger than the thickness of the transfer layer in the transfer portion.   The molding simultaneous transfer material according to claim 1, wherein the transfer layer of the non-transfer portion is formed by any one of a release layer, a design layer, an anchor layer, and an adhesive layer.

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