JP5119638B2 - Irregular decorative injection molded product - Google Patents

Description

  The present invention relates to a concavo-convex decorative injection molded product having a concavo-convex pattern on both the surface and the inner surface.

Injection molded products decorated by stacking and integrating decorative sheets as adherends on the surface side of resin molded products are used in various applications. In order to enhance the decorativeness of these injection molded products, it is widely performed to provide a three-dimensional design feeling by providing an uneven pattern such as a wood grain conduit groove.
As a method of providing this concavo-convex pattern, an embossing process that applies heat pressure to an ionizing radiation curable resin or a thermosetting resin base film is manufactured to produce a decorative sheet having a concavo-convex pattern, which is then injection-molded. A method used for forming an internal concavo-convex pattern is known. (For example, see Patent Document 1)
There has also been proposed a method of providing a concavo-convex pattern on the surface of an injection-molded product using a concavo-convex film obtained by applying a curable resin to a base film and then curing it to form a concavo-convex pattern. (For example, see Patent Documents 2 and 3)
However, when a decorative sheet with a concavo-convex pattern formed on the outer surface of a base film coated with a curable resin is used for injection molding, if the degree of cure of the curable resin is too low, it is decorated in a vacuum forming process. Due to the heat pressure when preforming the sheet and the heat pressure in the subsequent injection molding process, the uneven shape of the embossed uneven pattern tends to disappear, and if it is too high, the uneven pattern is likely to be distorted or cracked, There was a problem that the workability of the vacuum molding process and the injection molding process also deteriorated.
Furthermore, in order to emboss both surfaces of the decorative sheet, a nip is required with a metal-metal roll, but the thickness of the decorative sheet is often about 100 to 150 μm, and is 150 ° C. or higher, for example, 170 ° C. It is difficult to control the gap at a certain temperature. When the thickness of the decorative sheet is increased, the embossed uneven pattern may not enter due to the heat capacity, and the embossed uneven pattern disappears due to an increase in the required temperature during vacuum forming. It was.
Thus, at present, it is difficult to obtain an injection-molded product in which a concavo-convex pattern is formed on both the outer surface and the inner surface of the base film, and the three-dimensional design feeling of the concavo-convex pattern has not been sufficient.

Japanese Patent Laid-Open No. 7-32548 JP 7-32476 A Japanese Patent Laid-Open No. 2002-240078

  Under such circumstances, an object of the present invention is to provide an injection-molded product in which a complex concavo-convex pattern is formed and a higher-grade three-dimensional design is imparted.

As a result of intensive studies to achieve the above-mentioned problems, the present inventor has found that the above-mentioned problems can be solved by imparting a concavo-convex pattern to both the surface and the inner surface of an injection molded product. The present invention has been completed based on such findings.
That is, the gist of the present invention is as follows.
1. An injection molded article having a surface protective layer made of a transparent or translucent resin film, a colored layer laminated inside the surface protective layer, an adhesive layer laminated inside the colored layer, and an injection resin layer An uneven decorative injection molded product, wherein the surface of the surface protective layer, the colored layer, and the adhesive layer have an uneven pattern.
2. 2. The concavo-convex decorative injection-molded article according to 1 above, wherein the concavo-convex pattern on the surface of the surface protective layer is provided by the concavo-convex pattern on the cavity surface of the injection-molded mold subjected to the texture processing.
3. 3. The uneven decorative injection molded product according to 1 or 2 above, wherein the uneven pattern of the colored layer and the adhesive layer is provided by embossing the surface protective layer from the back surface.
4). 4. The uneven decorative injection molded product according to any one of 1 to 3, wherein the colored layer has a light reflecting layer.
5. 5. The uneven decorative injection molded product according to any one of 1 to 4 above, wherein the colored layer has a pattern printing layer and / or a colored solid layer.

  ADVANTAGE OF THE INVENTION According to this invention, the composite uneven | corrugated pattern is formed and the injection molded product to which the three-dimensional design property with a high-class feeling was provided can be provided.

Hereinafter, the present invention will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view of an uneven decorative injection molded product of the present invention.
As shown in FIG. 1, the uneven decorative injection molded product 1 of the present invention is laminated in the order of a surface protective layer 11, a colored layer 12, an adhesive layer 13 and an injection resin layer 20 from the surface side. Among these, the decorative sheet 10 is composed of the surface protective layer 11, the colored layer 12 and the adhesive layer 13.
The concave / convex pattern A including the convex portions 111 and the concave portions 112 viewed from the surface side of the surface protective layer 11 is given, and the convex portions 121 and the concave portions viewed from the surface side of the colored layer are also provided to the colored layer 12 and the adhesive layer 13. 122 and a concavo-convex pattern B including a convex portion 131 and a concave portion 132 viewed from the surface side of the adhesive layer is provided. These concavo-convex patterns A and B give depth to the concavo-convex pattern in a composite manner, and reveal a three-dimensional design with a high-class feeling.
FIG. 2 is a schematic plan view of the uneven decorative injection molded product 1 of the present invention.
The convex part 111 seen from the surface side of the surface protective layer 11 of the uneven decorative injection molded product 1 and the convex part 121 seen from the surface side of the colored layer 12 are combined in combination. This combination is not limited to this, and the convex portion 111 and / or the concave portion 112 constituting the concavo-convex pattern A and the convex portion 121 and / or the concave portion 122 constituting the concavo-convex pattern B may be combined.

FIG. 3 is a conceptual diagram illustrating one form (thermoject molding) of the injection molding method used in the present invention. The injection mold is composed of an injection mold (male mold) 31 and a suction injection mold (female mold) 32. In the vacuum forming step, the decorative sheet 10 is heated to a predetermined temperature, pressed and fixed to the suction injection mold (female mold) 32 by the sheet clamp 35, and then vacuum suction is performed from the suction hole 33 to complete the predetermined molding. . In the injection molding process immediately after that, the injection resin 34 is injected into the injection mold to form the injection resin layer 20. After the injection molding is completed and cooled, the concavo-convex decorative injection molded product 1 is taken out from the injection mold.
In order to give the concavo-convex pattern A to the surface of the surface protective layer 11 of the concavo-convex decorative injection-molded product 1 of the present invention, a suction-injection mold that has been embossed in the vacuum molding process and the injection molding process during injection molding The irregularities on the cavity surface of the (female mold) 32 may be transferred to the surface protective layer 11 under hot pressure. Here, the texture processing is one of metal fine processing methods for forming a pattern on the surface of the metal, and is also called chemical corrosion (etching) because the metal is mainly dissolved by a chemical.
The surface embossing depth of the front portion 36 of the mold is usually about 5 to 1,000 μm.

  In the present invention, the concavo-convex pattern A may be imparted to the surface of the injection mold (female mold) 32 by blasting the mold, scratching (scratching), etc. The embossing is preferable in that the target uneven pattern can be precisely processed.

Moreover, the uneven | corrugated pattern B of the colored layer 12 of the decorating sheet 10 and the adhesive bond layer 13 used for the uneven | corrugated decorative injection molded product 1 of this invention is embossed from the back surface to the surface protective layer 11 previously before injection molding. It can be given by. The embossing may be formed by pressing the embossed plate on the back surface side of the surface protective layer 11 of the decorative sheet 10 that has been heat-softened using a conventionally known hot-press type single-wafer or rotary embossing machine.
The embossing is usually performed by adjusting the depth so that the concavo-convex pattern B is appropriately provided on the back surface side of the surface protective layer 11. The embossing depth is preferably 40 to 60 μm in the uneven injection molded product.

As the surface protective layer 11 of the uneven decorative injection molded product 1 of the present invention, a transparent or translucent resin film is used. As the resin film, an acrylic resin film, a polycarbonate resin film, or the like that is excellent in transparency and, as a result, can impart an excellent coating feeling is preferable. The thickness of the resin film is preferably about 20 to 500 μm, more preferably about 50 to 150 μm.
Examples of the acrylic resin used for the resin film include polymethyl (meth) acrylate, polyethyl (meth) acrylate, polybutyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymer, and methyl (meth) acrylate. -Acrylic resin such as styrene copolymer [wherein (meth) acrylate means acrylate or methacrylate] is used as a single layer or a mixture of two or more types as a film of a single layer or a laminate of two or more layers. The surface protective layer 11 may be translucent, but it is preferable that the surface protective layer 11 is transparent to make the coloring layer 12 vividly colored. When it is transparent, it may be colored and transparent in addition to colorless and transparent. Further, in the resin film of the surface protective layer 11, if necessary, UV absorbers such as the above-mentioned matting agent, polyethylene wax, paraffin wax, and the like, benzotriazole-based, benzophenone-based, fine particle cerium oxide-based, etc. Various additives such as a light stabilizer such as an agent and a hindered amine radical scavenger, a plasticizer, a stabilizer and a colorant may be added to adjust the physical properties.

The colored layer 12 of the uneven decorative injection molded product 1 of the present invention preferably has a light reflecting layer. As the light reflection layer, for example, a metal thin film layer formed by depositing metal (aluminum, chromium, silver, etc.) on the back surface of the resin film, or a white coating film or metal having excellent reflectivity on the back surface. Examples thereof include a resin film having a glossy coating film. When the light reflecting layer is formed on the entire surface of the colored layer, it becomes a solid reflecting layer, and when it is partially formed, it becomes a pattern layer.
Further, the colored layer 12 according to the present invention may have a pattern printing layer and / or a colored solid layer in addition to the light reflecting layer or instead of the light reflecting layer. Furthermore, if desired, the colored layer 12 may have a functional layer such as a magnetic layer or a conductive layer. The magnetic layer includes a magnetic material, and the conductive layer includes a conductive material.

The colored layer 12 according to the present invention preferably has a colored solid layer, and in addition to the colored solid layer, it preferably has a design printing layer from the viewpoint of improving design. Usually, the pattern printing layer is printed outside the colored solid layer.
The colored solid layer and the pattern printing layer are basically not particularly limited, except that the binder resin is composed of a specific resin and an appropriate colorant for obtaining a desired color is blended. The colored solid layer and the pattern printing layer may be generally formed by a known printing method such as gravure printing, letterpress printing, silk screen printing, offset printing, and inkjet printing with a printing ink. The colored solid layer may be a known coating method such as roll coating.

The ink (or coating liquid) used for forming the pattern printing layer and the colored solid layer may be appropriately selected from known ones in consideration of adhesiveness and the like. For example, acrylic resin, vinyl chloride-vinyl acetate copolymer, polyester resin, polyurethane resin, etc. are usually used as the binder resin for the ink (or coating liquid). Among these, it is more preferable that the binder resin is mainly composed of an acrylic resin alone or a mixture of an acrylic resin and a vinyl chloride-vinyl acetate copolymer. When an acrylic resin is used as the surface protective layer 11, an acrylic resin is used to provide adhesion to the surface protective layer 11, and further, when mixed with a vinyl chloride-vinyl acetate copolymer or another acrylic resin, the printability and molding Suitability is further preferred.
Here, as an acrylic resin, it selects suitably from the thing similar to what was listed in the above-mentioned surface protective layer 11, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2- (Meth) acrylic acid alkyl esters such as ethylhexyl (meth) acrylate, octyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxybutyl (meth) acrylate, 2-hydroxy-3-phenoxypropyl (meth) An acrylic polyol obtained by copolymerizing a (meth) acrylic acid ester having a hydroxyl group in a molecule such as acrylate may also be used.
As the vinyl chloride-vinyl acetate copolymer, those having a vinyl acetate content of about 5 to 20% by mass and an average degree of polymerization of about 350 to 900 are usually used. If necessary, the vinyl chloride-vinyl acetate copolymer may be further copolymerized with a carboxylic acid such as maleic acid or fumaric acid. The mixing ratio of the acrylic resin and the vinyl chloride-vinyl acetate copolymer is about acrylic resin / vinyl chloride-vinyl acetate copolymer = 1/9 to 9/1 (mass ratio). In addition, as a subcomponent resin, if necessary, other resins such as thermoplastic polyester resin, thermoplastic urethane resin, chlorinated polyethylene, chlorinated polypropylene, and other chlorinated polyolefin resins may be mixed. Also good.
Examples of the colorant contained in the ink (or coating liquid) include inorganic pigments such as titanium white, zinc white, carbon black, iron black, petal, cadmium red, ultramarine, cobalt blue, chrome lead, and titanium yellow. Organic pigments such as phthalocyanine blue, indanthrene blue, isoindolinone yellow, quinacridone red, and perylene red (Pearl) pigments or dyes are used.
The pattern of the pattern layer and the pattern printing layer is, for example, a wood grain pattern, a stone pattern, a grain pattern, a cloth pattern, a leather pattern, a tiled pattern, a brickwork pattern, a geometric figure, a character, a symbol, and the like.

As the adhesive layer 13 used in the decorative sheet 10 of the present invention, for example, a known resin such as a thermoplastic resin or a thermosetting resin is used as a heat-sensitive adhesive. In the thermoplastic resin, for example, one or a mixture of two or more of acrylic resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer, thermoplastic urethane resin, thermoplastic polyester resin, polyamide resin, rubber resin, etc. Is used. In the thermosetting resin, a urethane resin, an epoxy resin, or the like is used.
The adhesive layer 13 is formed by known printing or coating methods such as gravure printing, roll coating, and the like using an adhesive made of these resins. The thickness of the adhesive layer 13 is not particularly limited, but is usually about 1 to 20 μm, preferably 1 to 10 μm.

The method for producing the decorative sheet 10 used for the uneven decorative injection molded product 1 of the present invention includes, for example, a metal thin film layer or a white coating on the back surface of another resin film on the back surface of the resin film to be the surface protective layer 11. The adhesive layer 13 may be applied after laminating the colored layer 12 composed of a light reflecting layer on which a film or a metallic gloss coating is formed. Further, if desired, a pattern printing layer may be printed on the surface of the light reflecting layer, and then the adhesive layer 13 may be applied to the back surface of the light reflecting layer. Further, instead of the light reflecting layer, the back surface of the resin film to be the surface protective layer 11 may be printed or coated in the order of the pattern printing layer and the colored solid layer, and then the adhesive layer 13 may be coated. .
Next, the decorative sheet 10 is embossed by a known method on the surface of the adhesive layer 13 by a known method. The decorative sheet temperature at the time of embossing is usually 150 ° C. or higher, for example, 200 to 240 ° C., and the embossed plate temperature is usually about 90 ° C. When the surface protective layer 11 is embossed from the back side, even when the injection resin is at a high temperature, the concave portion viewed from the back side of the adhesive layer 13 surface is immediately filled with the injection resin. The concavo-convex shape does not disappear.

The resin used for the injection resin layer 20 of the uneven decorative injection molded product 1 of the present invention is basically not particularly limited and may be a known resin. It may be selected according to the required physical properties and cost of the product. Examples of the thermoplastic resin include ABS (acrylonitrile-butadiene-styrene copolymer) resin, polycarbonate resin, styrene resin, acrylic resin, vinyl chloride resin, and polyolefin resin. Further, in the case of a curable resin, it is a two-component curable resin, for example, an uncured resin solution such as a urethane resin, an unsaturated polyester resin, or an epoxy resin. The thermoplastic resin is melted by heating and injected in a fluid state, and the curable resin (its uncured product) is injected at room temperature or appropriately heated and injected in a fluid state.
Note that as the injection resin, a resin colored by adding a colorant may be used as appropriate according to the application. As the colorant, a known colorant as described in the colored layer 12 may be used. The injection resin may contain various known additives such as silica, alumina, talc, calcium carbonate, aluminum hydroxide and other inorganic powders, fillers such as glass fibers, stabilizers, and lubricants as necessary. May be.

EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited at all by these examples.
Gravure printing a pattern print layer made of a polybutyl methacrylate / vinyl chloride-vinyl acetate copolymer (mass ratio: 2/1) composition on the back of a resin film (thickness 125 μm) made of acrylic resin (methyl methacrylate resin) In addition, a colored solid that contains a high gloss concealing pigment (titanium white and colored pigment) in the same composition as the pattern printing layer by gravure printing a metallic glossy coating on the part where the pattern printing layer is not printed. The layer was applied by roll coating, and an adhesive layer made of acrylic resin was further applied by roll coating. After drying, the surface protective layer is subjected to predetermined embossing from the back surface (to the adhesive layer surface side) (sheet temperature is controlled to 200 to 240 ° C. and embossing plate temperature is controlled to about 90 ° C.) to adhere to the colored layer. A decorative sheet having an uneven pattern on the agent layer was obtained.
This decorative sheet was heated to 100 ° C., vacuum-molded in an injection mold (mold temperature 60 ° C.), and brought into close contact with the injection mold (female mold, punch angle 5 °). Thereafter, in an injection molding process, ABS resin was injected at a resin pressure of 350 kg / cm ² and a resin temperature of 230 ° C., and heat and pressure were applied to the surface protective layer of the decorative sheet. Thereby, the resin film of the surface protective layer was deformed along the texture on the mold surface, and the texture pattern on the mold surface was transferred to the uneven decorative injection molded product. The surface embossing depth of the mold front part was 100 μm. Since the resin heat escapes to the mold at the moment when the resin comes into contact with the mold, the surface of the decorative sheet is about 90 ° C. After cooling, the appearance of the concave / convex decorative injection molded product taken out from the injection mold is three-dimensionally expressed by combining two types of concave / convex patterns of approximately the same shape by embossing and embossing. It was a feeling of luxury. Furthermore, a design feeling due to the texture (roughness) of the irregularities on the surface was obtained, and a combined effect with the design feeling by the visual appearance of the pattern could be achieved.

  The concavo-convex decorative injection-molded product of the present invention is suitably used for various automobile interior and exterior products, building / household interior products, high-end household goods, and the like.

It is a cross-sectional schematic diagram of the uneven | corrugated decoration injection molded product of this invention. It is a plane schematic diagram of the uneven | corrugated decoration injection molded product of this invention. It is a conceptual diagram explaining one form of the injection molding method utilized by this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Concave decoration injection molded product 10 Decorative sheet 11 Surface protective layer 111 Convex part seen from the surface side of the surface protective layer 112 Concave part seen from the surface side of the surface protective layer 12 Colored layer 121 Seen from the surface side of the colored layer Convex part 122 Concave part seen from the surface side of the colored layer 13 Adhesive layer 131 Convex part seen from the surface side of the adhesive layer 132 Concave part seen from the surface side of the adhesive layer 20 Injection resin layer 31 Injection mold (male Type)
32 Injection mold (female)
33 Suction hole 34 Injection resin 35 Sheet clamp 36 Front of mold

Claims (5)

After embossing from the adhesive layer side to the decorative sheet having a surface protective layer made of a transparent or translucent resin film, a colored layer, and an adhesive layer in this order, an uneven pattern is applied to the cavity surface. The mold having the surface protective layer is in contact with the surface protective layer, the resin is injected to the adhesive layer side, the uneven shape of the mold is transferred to the surface protective layer, and an injection resin layer is applied to the decorative sheet. A method for producing a concavo-convex decorative injection-molded product characterized by laminating . The manufacturing method according to claim 1, wherein the uneven shape of the mold is formed by embossing, and the embossed depth is 5 to 1000 μm . 3. The manufacturing method according to claim 1, wherein the emboss depth is 40 to 60 [mu] m. The said colored layer has a light reflection layer, The manufacturing method of any one of Claims 1-3 characterized by the above-mentioned . The said coloring layer has a pattern printing layer and / or a coloring solid layer, The manufacturing method of any one of Claims 1-4 characterized by the above-mentioned .

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