JP4404599B2 - Manufacturing method for simultaneously molded decorative molded products - Google Patents

Description

  In the simultaneous molding and transfer method, a transfer sheet having a transfer layer is disposed on a base sheet between the A mold and the B mold of an injection mold, and the mold is closed by closing the A mold and the B mold. In this method, a molding resin is injected into the molding space to form an injection molded product, and at the same time, a transfer layer is integrally bonded to the surface of the injection molded product.

  Recently, due to the need for improved design properties and improved physical properties of the surface of the molded resin, the simultaneous double-sided transfer method in which a transfer layer is provided on both sides as well as one side of the molded resin layer as in Patent Document 1 has attracted attention. ing. In the case of such a simultaneous molding double-sided transfer method, it is common to place the first transfer sheet and the second transfer sheet in both the A mold and the B mold and to inject the molding resin. It is.

JP-A-6-99457

  However, when the transfer layer is formed on both surfaces of the molding resin layer, when the mold is opened, the resulting molded simultaneous transfer molded product is held on the A mold side, on the B mold side, or either However, it may be dropped from the injection mold at the same time as the mold is opened, and it becomes difficult to collect the double-sided transfer molded products continuously and stably during mass production. It was.

  Therefore, the present inventor has made the following invention in order to solve the above problems.

In the present invention, a first transfer sheet having a first transfer layer provided on a base sheet is disposed in an A mold of an injection mold provided with an ejector pin, and a second transfer layer is provided on the base sheet. After the obtained second transfer sheet is placed in the B mold of the injection mold, a molding space is formed by clamping the A mold and the B mold, and a molding resin is injected into the molding space. Forming the injection molded product and simultaneously forming the first transfer layer and the second transfer layer, and a molding simultaneous decorative molded product manufacturing method, wherein the release weight of the first transfer layer from the base sheet, The release weight of the second transfer layer from the base sheet is set to 10 to 500 g weight / cm, and the release weight of the first transfer layer from the base sheet is set to be from the base sheet of the second transfer layer. It is set to 1.1 times or more of the mold release weight. Is obtained by way it is.

  Therefore, according to the method of manufacturing a simultaneous molding and transfer molding product of the present invention, the molding and simultaneous transfer molding product to be obtained is constantly held on the side of the A mold and molded by the ejector pin attached to the side of the A mold. Since the simultaneous transfer molded product can be ejected, the recovery device can always operate in the same direction, so that there is an effect that the simultaneous simultaneous double-sided transfer molded product can be recovered continuously and stably during mass production. .

  In addition, according to the first transfer sheet and the second transfer sheet according to the present invention, the molding simultaneous transfer molded product can be formed on the A mold without making it easy to hold the shape of the injection mold on the side of the A mold. Therefore, there is an effect that the selection range of the shape of the molded simultaneous transfer molded product is expanded.

  The invention of the method for producing a molded simultaneous transfer molded article of the first aspect of the present invention will be described below with reference to the drawings. In the method of manufacturing the molding simultaneous transfer molded product 10 of the present invention, the first transfer sheet 2 is disposed in the A mold 5 and the second transfer sheet 3 is disposed in the B mold 6. A molding space 12 is formed by closing the mold 6 and a molding resin 7 is injected from the gate 8 into the molding space 12 (see FIG. 1). The second transfer sheet 3 is formed by integrally forming the first transfer sheet on the back surface, and the molded simultaneous transfer molded product 10 is held in the A mold 5 after the mold is opened (see FIG. 2).

  The A mold 5 is formed in a rectangular shape or the like as in the prior art, and includes a reference surface 13 that directly contacts the B mold 6 at the peripheral end thereof. A concave portion 14 having a shape suitable for the outer shape of the molded product is formed in the inner portion surrounded by the reference surface 13 (see FIG. 6). On the other hand, the B mold 6 is formed in a square shape having a width and a height corresponding to the A mold 5, and includes a reference surface 13 that is a flat surface that directly contacts the A mold 5. A concave portion 14 having a shape suitable for the outer shape of the molded product is formed in the inner portion surrounded by the reference surface 13 (see FIG. 7).

  Then, the first transfer sheet 2 and the second transfer sheet 3 are sandwiched so that the reference surface 13 of the A mold 5 and the reference surface 13 of the B mold 6 are in contact with each other (see FIG. 1). In FIG. 7, the recess 14 (see FIG. 7) of the B mold 6 is arranged in the recess 14 (see FIG. 6) of the A mold 5. A molding space 12 is formed between the first transfer sheet 2 and the second transfer sheet 3, and a part of the concave portion 14 of the B mold 6 becomes a gate 8, and the molding resin 7 is molded through the gate 8. It is injected into the space 12 (see FIG. 1). The height, width, and thickness of the molding space 12 correspond to the predetermined height, width, and thickness of the molded product.

  When the molding resin 7 is injected into the molding space 12 and solidified, the molding resin layer 1, the first transfer sheet 2, and the second transfer sheet 3 are bonded and integrated. Thereafter, when the A mold 5 and the B mold 6 are opened, the release weight of the second transfer layer 30 is lower than the release weight of the first transfer layer 20, and thus the base sheet 21 of the second transfer sheet 3. The second transfer layer 30 is separated from the mold, the second transfer layer 30 is formed on the surface of the molding resin layer 1, and the molded simultaneous transfer molded product 10 in which the first transfer sheet 2 is bonded and integrated on the rear surface is the A mold 5 (See FIG. 2).

  Thereafter, the ejector pins 4 attached to the A mold 5 of the injection molding mold protrude the molded simultaneous transfer molded product 10, whereby the second transfer layer 20 is separated from the base sheet 21 of the first transfer sheet 2, and molding is performed. A simultaneous molding double-sided transfer molded article 11 is obtained in which the second transfer layer 30 is bonded to the front surface of the resin layer 1 and the first transfer layer 20 is bonded and integrated to the back surface (see FIG. 4).

  Then, the molding simultaneous double-sided transfer molded product 11 detached from the A mold 5 of the injection mold by the ejector pins 4 is taken out from the mold by the recovery device 15 (see FIG. 3). As a recovery method, there are a suction method by suction and a method of catching by pinching. The ejector pin 4 is driven by pressure such as hydraulic pressure.

  Next, the first transfer sheet 2 and the second transfer sheet 3 according to the present invention will be described.

  The first transfer sheet 2 and the second transfer sheet 3 are sheets on which a first transfer layer 20 and a second transfer layer 30 that can be peeled off after forming are formed on a base sheet 21. As an example of the first transfer layer 20 and the second transfer layer 30, there is a layer in which a release layer 22, a design layer 23, and an adhesive layer 24 are sequentially laminated (see FIG. 5). Then, after the first transfer sheet 2 and the second transfer sheet 3 are adhered to the molded resin layer 1, the respective base sheet 21 is peeled and removed, and the first transfer layer 20 and the second transfer layer 20 are formed on both surfaces of the molded resin layer 1. The molding simultaneous double-sided transfer molded product 11 in which the layer 30 is formed is obtained (see FIG. 4).

  Note that a release layer 25 for adjusting release from the release layer 22 may be formed on the base sheet 21. Moreover, when the design layer 23 has peelability, the release layer 22 may be omitted, and when the design layer 23 has adhesiveness, the adhesive layer 24 may be omitted. Also, an anchor layer 26 may be formed between the release layer 22 and the design layer 23 or between the design layer 23 and the adhesive layer 24 to improve the adhesion.

  The material of the base sheet 21 is preferably a polyester resin, a vinyl chloride resin, an acrylic resin, a polycarbonate resin, a polypropylene resin, a polyethylene resin, a polyurethane resin, a polystyrene resin, an acetate resin, a polyamide resin, or the like. .

  The film thickness of the base sheet 21 is preferably 5 μm to 5 mm. This is because if the film thickness is less than 5 μm, there is a problem that the sheet is not rigid and easily wrinkled, and if it is thicker than 5 mm, the sheet is too rigid and difficult to handle.

  The base sheet 21 may be formed by a general film forming method such as extrusion molding, calendar molding, or casting. In addition, the base sheet 1 may be subjected to easy adhesion treatment such as corona discharge treatment, plasma treatment, and easy adhesion primer coating on the surface on the side on which the printed layer is formed, if necessary.

  Examples of the material of the release layer 25 include melamine resin, silicon resin, fluorine resin, alkyd resin, and phenol resin, and a preferable material is appropriately selected according to the release property from the release layer. To do.

  The film thickness of the release layer 25 is preferably 0.5 μm to 50 μm. If the film thickness is less than 0.5 μm, there is a problem that sufficient releasability cannot be obtained, and if it is more than 50 μm, there is a problem that it is difficult to dry after printing.

  The method for forming the release layer 25 may be a method such as gravure printing, offset printing, or screen printing, or a method such as painting, dipping, or reverse coater.

  The release layer 22 is made of acrylic resin, vinyl resin, urethane resin, polyester resin, polypropylene resin, polyethylene resin, polystyrene resin, polycarbonate resin, vinylon resin, acetate resin, polyamide resin. Resin can be mentioned, A preferable material is suitably selected according to the peelability from a release layer.

  The thickness of the release layer 22 is preferably 0.5 μm to 50 μm. If the film thickness is less than 0.5 μm, there is a problem that sufficient peelability cannot be obtained, and if it is more than 50 μm, there is a problem that it is difficult to dry after printing.

  The method for forming the release layer 22 may be a method such as gravure printing, offset printing, or screen printing, or a method such as painting, dipping, or reverse coater.

  The pattern layer 23 is a layer on which a pattern to be decorated such as a wood grain pattern, a stone pattern, a cloth pattern, a character, a geometric pattern, a solid pattern and the like is formed. A plurality of design layers 23 may be formed in parallel. Moreover, you may provide a metal film layer in the pattern layer 23 as needed. In this case, the metal film layer may be entirely or patterned.

  Examples of the material for the pattern layer 23 include, but are not particularly limited to, polyester resins, acrylic resins, vinyl resins, nitrified cotton resins, urethane resins, and chlorinated rubber resins. In the case of a metal film layer, aluminum, chromium, copper, nickel, indium, tin, silicon oxide, and the like can be given, but there is no particular limitation. .

  The thickness of the pattern layer 23 is preferably 0.5 μm to 50 μm. When the film thickness is less than 0.5 μm, there is a problem that sufficient designability cannot be obtained, and when it is more than 50 μm, there is a problem that it is difficult to dry after printing. However, in the case of a metal film layer, 150 to 1200 mm is preferable. If the film thickness is less than 150 mm, there is a problem that sufficient designability cannot be obtained, and if it is more than 1200 mm, there is a problem that cracks are likely to occur.

  The pattern layer 23 may be formed by a method such as gravure printing, offset printing, or screen printing, or by a method such as painting, dipping, or reverse coater. In the case of a metal film layer, there are methods such as vacuum deposition and plating.

  The material of the adhesive layer 24 includes acrylic resin, vinyl resin, urethane resin, polyester resin, polypropylene resin, polyethylene resin, polystyrene resin, polycarbonate resin, vinylon resin, acetate resin, polyamide resin. Resin can be mentioned, A preferable material is suitably selected according to adhesiveness with molding resin.

  The film thickness of the adhesive layer 24 is preferably 0.5 μm to 10 μm. If the film thickness is less than 0.5 μm, there is a problem that sufficient adhesion cannot be obtained, and if it is more than 10 μm, there is a problem that it is difficult to dry after printing.

  The method for forming the adhesive layer 24 may be a method such as gravure printing, offset printing, or screen printing, or a method such as painting, dipping, or reverse coater.

  The material of the anchor layer 26 is acrylic resin, vinyl resin, urethane resin, polyester resin, polypropylene resin, polyethylene resin, polystyrene resin, polycarbonate resin, vinylon resin, acetate resin, polyamide resin. Resin can be mentioned, A preferable material is suitably selected according to adhesiveness with molding resin.

  The film thickness of the anchor layer 26 is preferably 0.5 μm to 10 μm. If the film thickness is less than 0.5 μm, there is a problem that sufficient adhesion cannot be obtained, and if it is more than 10 μm, there is a problem that it is difficult to dry after printing.

  The anchor layer 26 may be formed by a method such as gravure printing, offset printing, or screen printing, or by a method such as painting, dipping, or reverse coater.

  The first transfer sheet 2 and the second transfer sheet 3 are preferably in a long form such as a winding roll that can be set in a sheet feeding device. By fixing the first transfer sheet 2 to the sheet feeding device of the A mold 5 and the second transfer sheet 3 to the sheet feeding device of the B mold 6, the base sheet 21 and the second sheet 3 are fixed when the mold is opened and ejected. This is because the one transfer layer 20 and the second transfer layer 30 are easily separated.

  Further, the release weight of the first transfer layer 20 of the first transfer sheet 2 and the release weight of the second transfer layer 30 of the second transfer sheet 3 are preferably 10 to 500 g weight / cm. If it is less than 10 g weight / cm, the transfer layer moves due to the pressure at which the molding resin flows and cannot be formed at a desired position. If it exceeds 500 g weight / cm, the transfer sheet is transferred when the transfer sheet is peeled off from the transfer layer. This is because the layer may not release.

  The release weight of the first transfer layer 20 of the first transfer sheet 2 is preferably 1.1 times or more the release weight of the second transfer layer 30 of the second transfer sheet 3. This is because the molding simultaneous transfer molded product 10 may be held in the B mold when the ratio is less than 1.1 times (see Tables 1 and 2).

  The method for measuring the release weight of the first transfer layer 20 and the second transfer layer 30 is performed after the first transfer sheet 2 and the second transfer sheet 3 having a width of 1 cm are attached to the respective transfer target plates 17. The end of the transfer plate 17 is fixed with one chuck 16, and then the base sheet 21 is peeled off by 2 cm, bent at 180 °, fixed with the other chuck 16, and pulled at an environmental temperature of 25 ° C. to peel strength (See FIG. 8).

  A release layer composed of melamine resin and silicon resin in various ratios is formed on a base sheet composed of a polyethylene terephthalate film (easy adhesion treatment) with a thickness of 38 μm, and then a release layer using urethane resin-based two-component curable ink Was formed by a gravure printing method. After heat treatment at 120 ° C. for 5 minutes, a pattern layer made of an aluminum metal film having a thickness of 600 ± 50 mm is formed by vacuum deposition, and then an adhesive layer made of vinyl chloride vinyl acetate copolymer resin is formed by gravure printing. The first transfer sheets having various release weights were obtained.

  On the other hand, a release layer consisting of a melamine resin and a silicon resin having a weight percentage of 1: 1 is formed on a base sheet made of a polyethylene terephthalate film (easily adhesive treatment) having a thickness of 38 μm, and then a urethane resin-based two-component curable ink is used. The release layer was formed by gravure printing. After heat treatment at 120 ° C. for 5 minutes, a pattern layer made of an aluminum metal film having a thickness of 600 ± 50 mm is patterned by vacuum deposition, and then an adhesive layer made of vinyl chloride resin is formed by gravure printing. A second transfer sheet weighing 50 g weight / cm was obtained.

  The obtained first transfer sheet with various mold release weights is placed in an A mold of an injection mold having an ejector pin, and the second transfer sheet is placed in a B mold. After injecting a molding resin made of a polymer resin and cooling and solidifying it, the transfer layer of the first transfer sheet and the second transfer sheet and the molding resin are integrated, and then the injection mold is opened. was gotten.

  When the molding simultaneous transfer molded product is held on the mold A side, it has been possible to collect the molding simultaneous double-sided transfer molded product continuously and stably by a collecting device with a suction device.

  A release layer made of melamine resin is formed on a base sheet made of a polyethylene terephthalate film (easy adhesion treatment) with a thickness of 38 μm, and then a release layer made of acrylic resin and vinyl chloride vinyl acetate copolymer resin in various ratios is gravure. It was formed by a printing method. Subsequently, the pattern layer which consists of vinyl chloride vinyl acetate copolymer resin was formed by the gravure printing method, and the 1st transfer sheet of various mold release weight was obtained.

  On the other hand, a release layer made of a melamine resin is formed on a base sheet made of a polyethylene terephthalate film (easily adhesive treatment) having a thickness of 38 μm, and then an acrylic resin and a vinyl chloride / vinyl acetate copolymer resin are made up of 1: 1 by weight%. A release layer was formed by a gravure printing method. Next, a pattern layer made of a vinyl chloride resin was formed by a gravure printing method to obtain a second transfer sheet having a release weight of 100 g weight / cm.

  After placing the first transfer sheet of various release weights obtained on the A mold side of the injection mold attached with the ejector pins, the second transfer sheet is placed on the other B mold, A molding resin made of acrylonitrile styrene copolymer resin is injected, and after cooling and solidifying, the transfer layer of the first transfer sheet and the second transfer sheet and the molding resin are integrated, and then the injection mold is opened. Two results were obtained.

  When the molding simultaneous transfer molded product is held on the mold A side, it has been possible to collect the molding simultaneous double-sided transfer molded product continuously and stably by a collecting device with a suction device.

  Molded simultaneous double-sided transfer molded products obtained by the present invention include upper and lower lids of mobile phone devices, surface parts and exterior parts of electronic application toys, rice cooker input unit panels, automobile interior and exterior panels, pachinko machine outer frames, etc. Available to:

All of the drawings are obtained by using the method for producing a molded simultaneous transfer molded product according to the present invention, an injection mold used in the method, a first transfer sheet, a second transfer sheet, a release weight measuring device, and the like. An embodiment of the simultaneous molding double-sided transfer molded product is shown.
The first transfer sheet and the second transfer sheet are inserted between the A mold and the B mold, the mold resin is injected after the mold is clamped, and the injection shows the state where the mold resin is being filled into the molding space It is sectional drawing of a shaping die. It is sectional drawing of the metal mold | die for injection molding simultaneous decorating which shows the state by which the mold simultaneous transcription | transfer molded product was hold | maintained at A mold after mold opening. It is sectional drawing of the metal mold | die for simultaneous injection-molding decoration which shows the state which a collection | recovery apparatus collects a molding simultaneous double-sided transfer molded product. It is sectional drawing of the collect | recovered simultaneous simultaneous double-sided transfer molded product. It is sectional drawing of the 1st transfer sheet and 2nd transfer sheet which concern on this invention. It is sectional drawing of A metal mold | die of an injection mold. It is sectional drawing of the B metal mold | die of an injection mold. It is a schematic sectional drawing of a mold release weight measuring apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molding resin layer 2 1st transfer sheet 3 2nd transfer sheet 4 Ejector pin 5 A metal mold 6 B metal mold 7 Molding resin 8 Gate 10 Molding simultaneous transfer molding product 11 Molding simultaneous double-sided transfer molding product 12 Molding space part 13 Reference surface DESCRIPTION OF SYMBOLS 14 Recessed part 15 Collection | recovery apparatus 16 Chuck 17 Transfer board 20 1st transfer layer 21 Base sheet 22 Release layer 23 Design layer 24 Adhesive layer 25 Release layer 26 Anchor layer 30 Second transfer layer

Claims (1)

A first transfer sheet provided with a first transfer layer on a base sheet is placed in an A mold of an injection mold provided with an ejector pin , and a second transfer layer is provided on the base sheet . After the transfer sheet is placed in the B mold of the injection mold, a molding space is formed by clamping the A mold and the B mold, and a molding resin is injected into the molding space to perform injection molding. A method for producing a molded simultaneous decorative molded product in which a first transfer layer and a second transfer layer are integrally formed at the same time as the product is formed,
The release weight of the first transfer layer from the base sheet and the release weight of the second transfer layer from the base sheet are set to 10 to 500 g weight / cm,
The release weight of the first transfer layer from the base sheet is set to 1.1 times or more the release weight of the second transfer layer from the base sheet,
A method for producing a simultaneously molded decorative molded product, wherein the molded simultaneous decorative molded product is held in the A mold after the mold is opened.

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