JP4488485B2 - Metal gloss sheet and method for producing the same, method for producing metal gloss molded product - Google Patents

Description

  The present invention relates to a metallic glossy sheet, a method for producing the same, and a method for producing a metallic glossy molded product.

  Conventionally, as a method of performing decoration with a metallic luster such as a hairline pattern, a spin pattern, a mat pattern, or a knurled pattern on the surface of a plastic molded product, a method of printing a hairline pattern or the like on a thermoplastic sheet that can be three-dimensionally molded, There is a method of forming a fine uneven shape by transferring it by a transfer method.

  For printing a hairline pattern on a three-dimensionally moldable thermoplastic sheet, a plate such as a hairline pattern is prepared in advance by a known printing method such as an offset printing method, a gravure printing method, a screen printing method, or a flexographic printing method. In this method, the ink layer is transferred.

A method of forming a fine concavo-convex shape by transferring by a transfer method is a transfer material in which a transparent release layer, a metallic gloss layer, an adhesive layer, etc. are sequentially formed on the concavo-convex surface of a base sheet having a fine concavo-convex shape on the surface. After adhering the adhesive layer side to the resin molded product, heating and pressing, the base sheet is peeled off and removed from the release layer, so that the uneven shape of the base sheet is transferred to the surface of the release layer, and the hairline pattern Is applied to the surface of the molded product (see, for example, Patent Document 1).
JP-A-4-189200

  However, the metallic luster ornaments obtained by the methods described above have the following problems.

  In other words, the hairline pattern, etc. expressed by the method of printing the hairline pattern etc. on the thermoplastic sheet that can be molded three-dimensionally does not reach the fine line obtained by polishing the metal surface due to the limit of the accuracy of the printing method. It had the problem of not becoming something.

  In addition, the method of forming the fine concavo-convex shape by transferring by the transfer method has a problem that the fine concavo-convex shape is easily damaged because the surface exhibiting the fine concavo-convex shape is formed by the release layer.

  Accordingly, the present invention eliminates the above-mentioned problems and provides a metallic glossy sheet that can be decorated with a hairline pattern and the like that has a delicate fine uneven shape and is difficult to be damaged, and a method for producing the metallic glossy molded product. The purpose is to provide.

  In order to achieve the above object, the metallic glossy sheet of the present invention, the production method thereof, and the production method of the metallic glossy molded product are configured as follows.

  According to the first aspect of the present invention, a metallic gloss layer, a fine concavo-convex layer, and a transparent or translucent three-dimensional formable thermoplastic sheet on a base sheet made of a three-dimensional formable thermoplastic sheet. And a protective sheet made of at least one layer, the interface between the metallic luster layer and the fine concavo-convex layer has a fine concavo-convex shape, and the center line average roughness Ra of the fine concavo-convex layer is 0.2 ≦ Ra ≦ 0.8. A metallic glossy sheet is provided.

  According to the second aspect of the present invention, the metallic gloss layer and the fine uneven layer are sequentially laminated on the base sheet made of the thermoplastic sheet that can be three-dimensionally formed, and the metallic gloss layer and the fine uneven layer are Provided is a metallic glossy sheet in which the interface has a fine uneven shape, and the center line average roughness Ra of the fine uneven layer is 0.2 ≦ Ra ≦ 0.8.

  According to the third aspect of the present invention, the metallic luster layer is made of a mirror ink in which a powder of an aluminum vapor-deposited film is dispersed in a resin binder, and a standard black plate represented by Japanese Industrial Standard (JIS) K7105Gs (60 °). The metallic glossy sheet according to any one of the first and second aspects, wherein the 60 ° reflection gloss value Gs (60 °) of the metallic gloss layer exhibits a value of 80% or more when the numerical value is 100% is provided. To do.

  According to the fourth aspect of the present invention, a three-dimensionally moldable thermoplastic sheet in which a metallic luster layer and a fine uneven layer having a center line average roughness Ra of 0.2 ≦ Ra ≦ 0.8 are at least sequentially laminated. By laminating a protective sheet made of a transparent or translucent three-dimensional formable thermoplastic sheet on the fine uneven layer of the base material sheet made of, a fine uneven shape is formed at the interface between the metallic luster layer and the fine uneven layer. Provided is a method for producing a metallic glossy sheet.

  According to the fifth aspect of the present invention, the metallic gloss layer and the fine uneven layer having a center line average roughness Ra of 0.2 ≦ Ra ≦ 0.8 are formed on the base sheet as at least a constituent layer of the transfer layer. The transferred transfer material is transferred onto a base sheet made of a thermoplastic sheet that can be three-dimensionally molded so that the metallic gloss layer side is in contact, and after the base sheet is peeled off, the transparent or translucent three-dimensional moldable thermoplastic sheet There is provided a method for producing a metallic glossy sheet, in which a metallic glossy sheet having a fine irregularity shape at the interface between the metallic glossy layer and the fine irregularity layer is obtained by laminating a protective sheet made of

  According to the sixth aspect of the present invention, the fine concavo-convex layer of the base material sheet comprising the three-dimensionally moldable thermoplastic sheet in which the metallic gloss layer having a smooth surface and the fine concavo-convex layer having a smooth surface are sequentially laminated. A metallic gloss layer and a fine concavo-convex layer are formed by laminating a protective sheet having a centerline average roughness Ra of 0.2 ≦ Ra ≦ 0.8, which is made of a transparent or translucent three-dimensionally moldable thermoplastic sheet. Provided is a method for producing a metallic glossy sheet, which obtains a metallic glossy sheet having a fine irregular shape at the interface thereof.

  According to the seventh aspect of the present invention, a transparent or translucent three-dimensional molding in which a fine uneven layer having a center line average roughness Ra of 0.2 ≦ Ra ≦ 0.8 and a metallic luster layer are at least sequentially laminated. By laminating the surface on the metallic gloss layer side of the protective sheet made of a possible thermoplastic sheet on the base sheet made of a thermoplastic sheet that can be three-dimensionally molded, the interface between the metallic gloss layer and the fine uneven layer is fine. Provided is a method for producing a metallic glossy sheet that obtains a metallic glossy sheet having an uneven shape.

  According to the eighth aspect of the present invention, the fine uneven layer having a center line average roughness Ra of 0.2 ≦ Ra ≦ 0.8 and the metallic luster layer are formed on the base sheet as at least a constituent layer of the transfer layer. The transfer material is transferred onto a protective sheet made of a transparent or translucent three-dimensionally moldable thermoplastic sheet so that the fine concavo-convex layer side is in contact, and after the base sheet is peeled off, from the three-dimensionally moldable thermoplastic sheet Provided is a method for producing a metallic glossy sheet, in which a metallic glossy sheet having a fine concavo-convex shape at the interface between the metallic lustrous layer and the fine concavo-convex layer is obtained by laminating the base sheet to be formed on the metallic lustrous layer side.

  According to the ninth aspect of the present invention, the metallic glossy sheet of any one of the first to third aspects is molded into a desired shape in an injection mold, and the molten resin is injected onto the base sheet surface of the metallic glossy sheet. The present invention provides a method for producing a metallic glossy molded article that is integrally bonded and then removes unnecessary portions.

  According to the tenth aspect of the present invention, the metallic glossy sheet according to any one of the first to third aspects is molded into a desired shape outside the injection mold, and after unnecessary portions are removed, the metal glossy sheet is placed in the injection mold. Provided is a method for producing a metallic glossy molded article in which a molten resin is injected onto a base sheet surface of a metallic glossy sheet and integrally bonded to the molten resin.

  The metallic glossy sheet of the present invention comprises a metallic glossy layer, a fine concavo-convex layer, and a transparent or translucent three-dimensionally moldable thermoplastic sheet on a base sheet made of a thermoplastic sheet that can be molded three-dimensionally. The protective sheet is laminated at least sequentially, the interface between the metallic luster layer and the fine uneven layer has a fine uneven shape, and the center line average roughness Ra of the fine uneven layer is 0.2 ≦ Ra ≦ 0.8. Since it comprised, the decoration which has the metallic luster which consists of the fine uneven | corrugated shape which has a delicate pattern in which the surface is hard to be damaged is possible.

  Further, the method for producing a metallic glossy sheet of the present invention is capable of three-dimensional molding in which a metallic glossy layer and a fine uneven layer having a center line average roughness Ra of 0.2 ≦ Ra ≦ 0.8 are at least sequentially laminated. By laminating a protective sheet made of a transparent or translucent three-dimensional formable thermoplastic sheet on the fine uneven layer of a base sheet made of a thermoplastic sheet, a fine layer is formed at the interface between the metallic luster layer and the fine uneven layer. Since the metallic glossy sheet having the concavo-convex shape is obtained, it is possible to easily obtain a metallic lustrous sheet that can be decorated with a metallic luster having a fine concavo-convex shape that has a delicate pattern and the surface is not easily damaged.

  In addition, the method for producing a metallic glossy molded product of the present invention is a method in which the above metallic glossy sheet is molded into a desired shape in an injection mold, and a molten resin is injected onto the base sheet surface of the metallic glossy sheet for integrated bonding. After that, since it is configured to remove unnecessary portions, it is possible to easily obtain a metallic gloss molded article having a metallic luster having a fine uneven shape having a delicate pattern that is hard to damage the surface.

  Embodiments of the present invention will be described in detail with reference to the drawings.

  1 and 2 are cross-sectional views showing an embodiment of the metallic glossy sheet of the present invention. FIG. 3 is a cross-sectional view showing an embodiment of a transfer material used in the method for producing a metallic glossy sheet of the present invention. FIG. 4 is a cross-sectional view showing one step of the method for producing a metallic glossy sheet of the present invention. FIG. 5 is a sectional view showing an embodiment of the metallic glossy sheet of the present invention. FIG. 6 is a cross-sectional view showing an embodiment of a transfer material used in the method for producing a metallic glossy sheet of the present invention. FIG. 7 is a cross-sectional view showing one step of the method for producing a metallic glossy sheet of the present invention. FIG. 8 is a cross-sectional view showing an embodiment of the metallic glossy sheet of the present invention. FIG. 9 is a cross-sectional view showing one step of the method for producing a metallic glossy sheet of the present invention. FIG. 10 is a cross-sectional view showing an embodiment of the metallic glossy sheet of the present invention. FIG. 11 is a cross-sectional view showing one step of the method for producing a metallic glossy sheet of the present invention. FIG. 12 is a cross-sectional view showing an example of a transfer material used in the method for producing a metallic glossy sheet of the present invention. FIGS. 13-14 is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. FIG. 15 is a cross-sectional view showing an embodiment of the metallic glossy sheet of the present invention. 16-20 is sectional drawing which shows 1 process of the manufacturing method of the metallic luster molded product of this invention. FIG. 21 is a cross-sectional view showing an embodiment of a metallic gloss molded product obtained by the method for producing a metallic gloss molded product of the present invention. FIG. 22 is a cross-sectional view showing one step of the method for producing a metallic glossy sheet of the present invention. FIG. 23 is a graph showing a formula for obtaining the centerline average roughness.

  In the figure, 10 is a metallic gloss sheet, 11 is a base sheet, 12 is a metallic gloss layer, 13 is a fine uneven layer, 14 is a protective sheet, 20 is a transfer material, 21 is a base sheet, 22 is an adhesive layer, and 30 is gold. A mold, 31 is a clamp, 32 is a heating device, 33 is a suction hole, 40 is a metallic gloss molded product, and 41 is a molding resin.

  The metallic glossy sheet 10 of the present invention has a metallic glossy layer 12, a fine uneven layer 13, and a transparent or translucent three-dimensionally moldable heat on a base sheet 11 made of a thermoplastic sheet that can be three-dimensionally molded. The protective sheet 14 made of a plastic sheet is laminated at least sequentially, the interface between the metallic luster layer 12 and the fine uneven layer 13 has a fine uneven shape, and the center line average roughness Ra of the fine uneven layer 13 is 0.2 ≦ Ra. ≦ 0.8 (see FIG. 1).

  As the base material sheet 11, a three-dimensionally moldable thermoplastic sheet is used. As a material for the base sheet 11, a resin sheet such as a polypropylene resin, a polyethylene resin, a polyamide resin, a polyester resin, an acrylic resin, or a polyvinyl chloride resin may be used. In particular, in consideration of heat resistance and dimensional stability, it is preferable to use polyethylene terephthalate.

  The metallic luster layer 12 is a layer that consists of a metal thin film layer or a printed layer and expresses metallic luster. The metallic luster layer 12 is formed entirely or partially.

  The metal thin film layer uses a metal such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, or an alloy or compound thereof depending on the metallic luster color to be expressed. can do. In particular, considering the stretchability and resistance of the metal thin film layer, it is preferable to use chromium, indium, tin, an alloy or a compound thereof. The metal thin film layer may be formed by a transfer method, a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. In particular, it is preferably formed by a transfer method. This is because the transparent fine uneven layer 13 can be formed together with the metallic gloss layer 12. The transfer method will be described later.

  Moreover, the metallic luster layer 12 can also be formed by the printing layer using the ink which used metal powder etc. as the pigment. As the ink, it is preferable to use a mirror ink obtained by pulverizing an aluminum deposited layer and dispersing it in a resin binder. When aluminum particles having low specular reflection are used as the pigment, it is difficult to effectively express the unevenness when the protective sheet 14 is laminated due to irregular reflection of light, and therefore mirror ink capable of obtaining specular reflection is used. Is preferred. In particular, when the value of the reference black plate shown in Japanese Industrial Standard (JIS) K7105Gs (60 °) is 100%, the 60 ° reflection gloss value Gs (60 °) of the metallic gloss layer shows a value of 80% or more. If it is a thing, an uneven | corrugated feeling can be expressed effectively.

  As a method for forming the metallic gloss layer 12 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 addition, when providing the metallic luster layer 12, you may provide a front anchor layer and a rear anchor layer in order to improve adhesiveness with another 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.

  The fine uneven layer 13 is a layer provided for expressing fine unevenness by acting together with the metallic luster layer 12. The interface between the metallic luster layer 12 and the fine uneven layer 13 is configured to have a fine uneven shape. In the present invention, it is important that the center line average roughness Ra of the fine uneven layer 13 is 0.2 ≦ Ra ≦ 0.8. The center line average roughness Ra of the fine concavo-convex layer 13 means that only the reference length (L) is extracted from the roughness curve in the direction of the average line, the x axis in the direction of the extracted portion, and the y axis in the direction of the vertical magnification. Is represented by the following equation when y is expressed as y = f (x) (see FIG. 23).

  When the center line average roughness is in the above range, even if the protective sheet 14 is laminated on the surface in a later step, the fine uneven shape does not disappear. If the center line average roughness Ra is less than 0.2, it is difficult to leave a fine uneven shape after the protective sheet 14 is laminated. On the other hand, when the center line average roughness Ra exceeds 0.8, when the protective sheet 14 is laminated, the unevenness is too large, and air may be bitten and cause adhesion failure.

  In order to form the fine uneven layer 13, it is preferable to use a transfer method. According to the transfer method, it is easy to form the fine uneven layer 13 having an arbitrary roughness into an arbitrary pattern. The transfer method uses a transfer material 20 in which a transfer layer composed of a fine uneven layer 13, a metallic luster layer 12, an adhesive layer 22, etc. is formed on a base sheet 21, and is heated and pressed to apply the transfer layer to the substrate sheet 11. After the contact, the base sheet 21 is peeled off, and only the transfer layer is transferred onto the base sheet 11 for decoration.

  The transfer material 20 uses a substrate sheet 21 on which a transfer layer composed of at least the fine uneven layer 13 is laminated (see FIGS. 3 and 6).

  As a material of the base sheet 21, a material used as a base sheet of a normal transfer material such as a polypropylene resin, a polyethylene resin, a polyamide resin, a polyester resin, an acrylic resin, or a polyvinyl chloride resin should be used. Can do. In particular, a fine uneven shape is formed on the surface of the base sheet 21. By peeling off the base sheet 21 in a later step, the fine uneven shape of the base sheet 21 is copied to the fine uneven layer 13 to express a fine uneven shape such as a hairline pattern, a spin pattern, a mat pattern, or a knurled pattern. Can do.

  As a method for creating a fine uneven shape on the surface of the base sheet 21, there is a film excavation method in which the surface of the base sheet 21 is scratched by rubbing with a nonwoven fabric, a wire brush, sandpaper, steel wool or the like. Further, there is a matting agent kneading method in which a matting agent is kneaded into a material of the base sheet 21 and the matting agent is raised on the surface in a sheeted state. In addition, there is a mat agent coating method in which an ink in which a resin, a mat agent, and a solvent are mixed is coated on the base sheet 21, and after the solvent is dried, the mat agent is raised on the resin surface to make the surface uneven. Further, there is a pressing method in which the base sheet 21 made of a thermoplastic resin is pressed with a concavo-convex mold by applying pressure while applying heat in the vicinity of the softening point or higher, and the concavo-convex pattern is copied on the surface by the principle of embossing.

  When the peelability of the base sheet 21 from the fine uneven layer 13 is good, the fine uneven layer 13 may be provided directly on the base sheet 21. In order to improve the peelability of the base sheet 21 from the fine uneven layer 13, a release layer (not shown) may be formed on the entire surface before the fine uneven layer 13 is provided on the base sheet 21. . The release layer is removed from the fine uneven layer 13 together with the base sheet 21 when the base sheet 21 is peeled off after 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.

  The fine uneven layer 13 is formed entirely or partially on the base sheet 21 or the release layer. When the substrate sheet 21 is peeled off after the transfer, the fine uneven layer 13 copies the fine uneven shape of the substrate sheet 21. The material of the fine uneven layer 13 includes acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, and also vinyl chloride-vinyl acetate. Copolymers such as polymer resins and ethylene-vinyl acetate copolymer resins may be used. When hardness is required, a photocurable 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 fine uneven layer 13 may be colored or uncolored. Examples of the method for forming the fine uneven layer 13 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.

  When the fine uneven layer 13 is a thermoplastic resin, if the fine uneven layer 13 is formed as thin as possible and the metal gloss layer 12 described later is formed thereon, the metal gloss layer 12 also has an uneven shape. Even if the surface of the fine uneven layer 13 in contact with the protective sheet 14 is crushed when the protective sheet 14 is laminated, the uneven shape of the metallic luster layer 12 remains without disappearing (see FIGS. 3 to 5).

  When the fine concavo-convex layer 13 is a thermosetting resin, the concavo-convex shape on the surface of the fine concavo-convex layer 13 on the side in contact with the protective sheet 14 is pressed by the pressure when the protective sheet 14 is laminated. Uneven shape can be generated at the interface with the metallic luster layer 12 (see FIGS. 6 to 8).

  A metallic gloss layer 12 may be formed on the transfer material 20 instead of the metallic gloss layer 12 directly formed on the base sheet 11 (see FIGS. 3 and 6). By forming the metallic gloss layer 12 on the transfer material 20, the metallic gloss layer 12 can be laminated on the base sheet 11 together with the fine uneven layer 13. The metallic gloss layer 12 may be formed on the transfer material 20 by the same method as described above.

  Moreover, you may form a design layer (not shown) as needed. The design layer is a layer that expresses decoration in addition to the metallic luster of the metallic luster layer 12, and more specifically, designs such as letters and symbols, solid patterns, wood grain patterns, stone grain patterns, carbon cloth Examples include patterns such as patterns. By forming the design layer on the transfer material 20, the design layer can be laminated on the base material sheet 11 together with the fine uneven layer 13. As a material of the pattern 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. As a pattern layer forming method, a normal printing method such as a gravure printing method, a screen printing method, or an offset printing method may be used.

  Moreover, you may form the contact bonding layer 22 as needed (refer FIG. 3, 6). As the adhesive layer 22, a heat sensitive or pressure sensitive resin suitable for the material of the base sheet 11 is appropriately used. For example, when the material of the base sheet 11 is an acrylic resin, an acrylic resin may be used. When the material of the base sheet 11 is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, A polyamide resin or the like may be used. Furthermore, when the material of the base sheet 11 is 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 22 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.

  Using the transfer material 20 having such a layer structure, the metallic gloss layer 12 and the fine uneven layer 13 can be formed on the base sheet 11 (see FIGS. 4 and 7).

  First, the metallic gloss layer 12 side of the transfer material 20 is brought into close contact with one side of the base material sheet 11.

  Next, using a transfer machine such as a roll transfer machine or an up-down transfer machine equipped with a heat-resistant rubber-like elastic body such as silicon rubber, a heat-resistant rubber-like condition set at a temperature of about 80 to 260 ° C. and a pressure of about 490 to 1960 Pa. Heat and pressure are applied from the substrate sheet 21 side of the transfer material 20 through the elastic body. By doing so, the metallic gloss layer 12 side of the transfer material 20 adheres to the surface of the base material sheet 11. When the substrate sheet 21 is peeled off after cooling, peeling occurs between the substrate sheet 21 and the fine uneven layer 13 and transfer is completed. When a release layer (not shown) is provided on the base sheet 21, when the base sheet 21 is peeled off, peeling occurs between the release layer and the fine concavo-convex layer 13 and transfer is completed. In this way, the metallic luster layer 12 and the fine uneven layer 13 can be formed on the substrate sheet 11.

  When the metallic gloss layer 12 is not a constituent element as the transfer layer of the transfer material 20, the metallic gloss layer 12 is formed on the base sheet 11 in advance, and the transfer material 20 is used on the metal gloss layer 12. Layer 13 will be formed (not shown).

  Next, the protective sheet 14 is laminated. As the protective sheet 14, a transparent or translucent three-dimensionally moldable thermoplastic sheet is used. The protective sheet 14 may be made of an acrylic resin, a polycarbonate resin, a polycarbonate polyester alloy resin, a polyacrylonitrile resin, or a fluorine resin in consideration of the intended use of the metallic gloss molded product 40. For example, switch bases and center clusters for automobile interiors require acrylic resin for light resistance and scratch resistance, and heater control panels for automobile interiors require impact resistance and transparent color screen printing. Because of this, polycarbonate resin is used for mobile phone casings, etc. for the purpose of scratch resistance and prevention of film melt due to friction, and fluorine resin is used for toilets and bathtubs in consideration of chemical resistance. May be selected respectively.

  Further, the protective sheet 14 may contain a transparent colorant, a light diffusing agent, and the like. Examples of the light diffusing agent include metal oxides such as silicon oxide, magnesium carbonate, aluminum stearate, magnesium silicate, and metal palmitate, resin wax such as polyethylene, and acrylic acid rubber.

  In order to laminate the protective sheet 14, it is preferable to use a laminating method in consideration of stable adhesion and surface finish. Examples of the laminating method include an extrusion laminating method, a hot melt laminating method, a thermal laminating method, and a dry laminating method. In particular, the thermal laminating method is preferable because it is excellent in winding property, adhesion, and adaptability of the protective sheet thickness.

  Thus, by laminating | stacking the protection sheet 14, the fine uneven | corrugated layer 13 will be covered with the protection sheet 14, and a dirt will not accumulate in the recessed part of a delicate hairline pattern. Further, the protective sheet 14 plays a role of preventing damage.

  The metallic glossy sheet 10 of the present invention is not limited to the above configuration, and may be configured as follows.

  For example, when the design layer is not formed using the transfer material 20, a design layer may be separately provided (not shown).

  Moreover, in order to improve the adhesiveness of the protective sheet 14 and the fine uneven | corrugated layer 13, you may form a contact bonding layer as needed (not shown).

  Moreover, you may form another contact bonding layer in the surface opposite to the surface where the protective sheet 14 of the base material sheet 11 is laminated | stacked as needed (not shown). The adhesive layer adheres the metallic gloss sheet 10 to the surface of the molded product that is decorated with the metallic gloss sheet 10. As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the surface of the molding resin 41 is appropriately used.

  Further, the metallic gloss sheet 10 may be configured such that at least the fine uneven layer 13 and the metallic gloss layer 12 are sequentially laminated on the base material sheet 11 without stacking the protective sheet 14 (see FIG. 2). . Since the protective sheet 14 is not laminated, the manufacturing process of the metallic glossy sheet 10 can be shortened. Since the surface of the fine concavo-convex layer 13 does not have a concavo-convex shape, the concave portions of the delicate hairline pattern do not accumulate dirt, and are difficult to be damaged.

  Further, in order to make the interface between the metallic luster layer 12 and the fine concavo-convex layer 13 have a fine concavo-convex shape, the fine concavo-convex is formed on the protective sheet 14 side, and the metallic lustrous layer 12 and the fine concavo-convex layer 13 (at this time) It may be laminated with the base material sheet 11 laminated (without the irregular shape) (see FIGS. 9 and 10). The fine irregularities formed on the protective sheet 14 can be formed by a film excavation method, a mat agent kneading method, a mat agent coating method, a pressing method, or the like.

  Further, the protective sheet 14 having the fine uneven layer 13 having the fine unevenness and the metallic gloss layer 12 may be laminated on the base sheet 11 to obtain the metallic gloss sheet 10 (see FIG. 11).

  Moreover, you may form the fine uneven | corrugated layer 13 in the protective sheet 14 side by the transfer method mentioned above (refer FIGS. 12-15). In this case, since the order of lamination of the transfer layers after transfer is reversed from the case described above, the metallic gloss layer 12 is first formed on the base sheet 21, and then the fine uneven layer 13 is formed (see FIG. 12). .

  In order to obtain the metallic glossy molded product 40 using the metallic glossy sheet 10 having such a configuration, the metallic glossy sheet 10 is molded into a desired shape in the injection mold 30 and the base sheet 11 surface of the metallic glossy sheet 10 is obtained. The molten resin is injected into and integrally bonded, and then unnecessary portions are removed. Specifically, it may be performed as follows.

  First, the metallic glossy sheet 10 is set in an injection mold 30 (see FIG. 16).

  As a specific example of how to set to the injection mold 30, the long metallic glossy sheet 10 is temporarily wound around a roll shaft to form a roll-shaped roll, and this roll-shaped roll is an upper part of the movable mold for injection molding. The metallic glossy sheet 10 is unwound from the roll-shaped scroll and passed between the retracted movable mold and the stationary mold, and is placed under the movable mold for injection molding. What is necessary is just to wind up the metallic glossy sheet 10 with the roll axis | shaft of the film winding means installed so that a movement type | mold and movement were possible. Alternatively, the metallic glossy sheet 10 may be set on a movable surface by a robot or manually. When the metallic gloss sheet 10 is set on the movable surface, the metallic gloss sheet 10 is placed on the movable surface, and the position of the metallic gloss sheet 10 with respect to the movable surface is determined by a positioning sensor or the like. The sheet 10 may be pressed against the surface of a movable mold for injection molding by a clamp 31 or the like.

  Next, the metallic gloss sheet 10 is molded into a desired shape in the injection mold 30. As a specific example, with a heating plate inserted between a movable mold and a fixed mold, the metallic glossy sheet 10 set on the surface of the movable mold is heated above its softening point and softened (see FIG. 17). The space between the concave portion of the mold and the metallic glossy sheet 10 is sealed and evacuated from the vacuum suction hole 33 formed in the movable die, and vacuum suction is performed, and the metallic glossy sheet 10 is brought into close contact with the inner surface of the concave portion of the movable die (see FIG. 18), there is a method of processing into a three-dimensional shape so as to follow a movable concave portion, that is, a cavity forming surface.

  Further, instead of the above method, before setting the metallic glossy sheet 10 to the injection mold 30, the metallic glossy sheet 10 is pre-injected using a three-dimensional machining mold different from the injection mold 30. Three-dimensional processing may be performed into a shape that matches the cavity forming surface of the molding die 30, and unnecessary portions may be removed by a method such as punching to obtain a desired shape. As a three-dimensional processing method, there are a vacuum forming method, a pressure forming method, a press forming method for pressing a heated rubber, a press forming method, and the like. Examples of the punching method include a Thomson punching method and a press method using a die. In addition, you may perform a punching process simultaneously in the case of a three-dimensional process.

  Next, the mold 30 for injection molding is closed, and the molten molding resin 41 is injected into the cavity from the gate portion of the fixed mold, and the molding resin 41 is solidified to form a resin molded product in the cavity. The metallic glossy sheet 10 is integrally bonded to the surface (see FIG. 19).

  The molding resin 41 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 41 used for interior parts and exterior parts of automobiles, there can be mentioned polypropylene resin containing talc, modified polypropylene resin, and the like.

  Thereafter, the mold is opened and the metallic glossy sheet 10 is taken out together with the resin molded product (FIG. 20), and unnecessary portions of the metallic glossy sheet 10 adhered to the resin molded product are removed. In addition, when the metallic glossy sheet 10 is punched in advance, an operation for removing unnecessary portions of the metallic glossy sheet 10 is not necessary. In this way, a metallic gloss molded product 40 can be obtained (see FIG. 21).

  A housing upper for automobile interior was produced as follows.

  A polyethylene terephthalate film having a thickness of 25 μm was used as a transfer material base sheet, and the surface thereof was processed using a nonwoven fabric so as to exhibit a hairline pattern having a center line average roughness Ra = 0.5. Next, an acrylic ink was applied thereon with a thickness of 1.0 to 1.5 μm by a gravure printing method to form a fine uneven layer. Subsequently, chromium was vapor-deposited to a thickness of about 40 μm by a vacuum vapor deposition method to form a metallic luster layer. Next, an ink made of vinyl chloride-vinyl acetate copolymer resin was applied to the thickness of 2.0 to 3.0 μm by gravure printing to form an adhesive layer, and a transfer material was obtained.

  The transfer material thus obtained was transferred to the surface of the base material sheet made of ABS resin by a thermal laminating apparatus, the base sheet was peeled off, and then a protective sheet made of acrylic resin was over-laminated on the surface of the fine concavo-convex layer. A glossy sheet was obtained. The transfer, substrate sheet peeling, and protective sheet laminating processes described above were performed in a series of roll-to-roll processes. Further, the center line average roughness Ra of the fine uneven layer of the metallic glossy sheet was 0.43.

  The metallic glossy sheet thus obtained is attached to a vacuum forming die, heated so that the surface temperature becomes 170 ° C., vacuumed to obtain a desired shape, and then unnecessary portions are cut. It was inserted into a molding die, heat-resistant ABS resin at 245 ° C. was injected as a molten resin, and integrally bonded to obtain a metallic gloss molded product.

  The metallic glossy molded product thus obtained was hard to be damaged because the surface was flat while maintaining a delicate hairline.

  A cellular phone casing was produced as follows.

  A polyethylene terephthalate film having a thickness of 38 μm was used as a transfer material base sheet, and the surface thereof was processed using a gold brush so as to exhibit a hairline pattern with a centerline average roughness Ra = 0.8. Next, a fine concavo-convex layer was formed thereon by applying a vinyl chloride ink with a thickness of 1.0 to 1.5 μm by a gravure printing method. Next, an aluminum vapor deposited film was pulverized and dispersed in a polyamide / nitrified cotton-based ink to a thickness of 5.0 μm by a lip coating method to form a metallic gloss layer of Gs (60 °) = 103. Next, an ink composed of a vinyl chloride-vinyl acetate copolymer resin was applied to a thickness of 2.0 to 3.0 μm by a gravure printing method to form an adhesive layer, and a transfer material was obtained.

  The transfer material thus obtained was transferred to a base material sheet made of a polycarbonate film having a thickness of 200 μm to obtain a metallic glossy sheet. Further, the center line average roughness Ra of the fine uneven layer of the metallic glossy sheet was 0.62.

  The metallic glossy sheet thus obtained was supplied to an injection mold by a supply device, and vacuum suction was performed while heating until the surface reached 185 ° C. to obtain a desired shape. Thereafter, the polycarbonate resin was integrally bonded to the molten resin having a resin temperature of 275 ° C., and unnecessary portions were removed with a router to obtain a metallic gloss molded product.

  The metallic glossy molded product thus obtained was hard to be damaged because the surface was flat while maintaining a delicate hairline.

  The present invention is suitable for automobile interior parts such as console panels, center clusters, and switch bases, automobile exterior parts such as side mat guards, bumpers, foil caps, and moldings, cellular phone casing parts, and cellular phone lens parts. It can be used for industrial purposes.

It is sectional drawing which shows one Example of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the transfer material used for the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the transfer material used for the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the transfer material used for the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows one Example of the metallic glossy sheet | seat of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic luster molded product of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic luster molded product of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic luster molded product of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic luster molded product of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic luster molded product of this invention. It is sectional drawing which shows one Example of the metallic luster molded product obtained by the manufacturing method of the metallic luster molded product of this invention. It is sectional drawing which shows 1 process of the manufacturing method of the metallic glossy sheet | seat of this invention. It is a graph which shows the formula which calculates | requires centerline average roughness.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Metal gloss sheet 11 Base material sheet 12 Metal gloss layer 13 Fine uneven | corrugated layer 14 Protection sheet 20 Transfer material 21 Base sheet 22 Adhesive layer 30 Mold 31 Clamp 32 Heating device 33 Suction hole 40 Metal gloss molded product 41 Molding resin

Claims (3)

A metallic glossy sheet having a transfer layer transferred from a substrate sheet or a release layer having a fine irregular shape formed on the surface,
A base sheet made of a three-dimensionally moldable thermoplastic sheet;
The transfer layer comprising a metallic luster layer laminated on the base sheet, and a fine uneven layer made of a thermoplastic resin laminated on the metallic luster layer;
A protective sheet made of a transparent or translucent three-dimensionally formable thermoplastic sheet laminated so as to cover the fine uneven layer;
The thickness of the metallic luster layer and the fine concavo-convex layer is such that the top surface and the bottom surface conform to the fine concavo-convex shape in a state before transfer when formed on the surface of the base sheet or the release layer. Is set to
Wherein the metallic luster layer interface with the fine uneven layer is formed on the fine irregularities, the center line average roughness Ra of the fine uneven layer is 0.2 ≦ Ra ≦ 0.8, metallic luster sheet.   The metallic gloss layer is made of mirror ink in which powder of an aluminum vapor-deposited film is dispersed in a resin binder, and when the value of a standard black plate represented by Japanese Industrial Standard (JIS) K7105Gs (60 °) is 100%, The metallic glossy sheet according to claim 1, wherein the glossy layer has a 60 ° reflection gloss value Gs (60 °) of 80% or more. A base sheet made of a three-dimensionally moldable thermoplastic sheet, a metallic luster layer laminated on the base sheet, and a fine uneven layer made of a thermoplastic resin laminated on the metallic luster layer; A protective sheet made of a transparent or translucent three-dimensionally moldable thermoplastic sheet laminated so as to cover the fine uneven layer, and the interface between the metallic luster layer and the fine uneven layer has a fine uneven shape. The center line average roughness Ra of the fine concavo-convex layer is set to 0.2 ≦ Ra ≦ 0.8.
Forming a fine concavo-convex shape on the surface of the base sheet so that the center line average roughness Ra is 0.2 ≦ Ra ≦ 0.8;
Forming the fine concavo-convex layer on the fine concavo-convex shape formed so that the upper surface has a shape along the fine concavo-convex shape;
The metallic gloss layer is formed on the fine concavo-convex layer so that the upper surface has a shape along the fine concavo-convex shape, and the interface between the metallic gloss layer and the fine concavo-convex layer, and the metallic gloss layer Forming a surface opposite to the interface in a fine concavo-convex shape to produce a transfer material,
The surface of the metallic gloss layer side of the produced transfer material is closely adhered to the base sheet, the base sheet is peeled off, and the fine uneven layer and the metallic gloss layer are transferred to the base sheet;
And a step of laminating the protective sheet so as to cover the transferred fine concavo-convex layer.

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