JP5152070B2 - Decorative sheet, decorative molded product, and injection molding simultaneous decoration method - Google Patents

Description

  The present invention relates to a decorative sheet having a three-dimensional design feeling of a concavo-convex pattern, a decorative molded product using the decorative sheet, and an injection molding simultaneous decorative method for forming the decorative molded product.

  A decorative molded product decorated as an adherend by laminating and integrating decorative sheets on the surface of a resin molded product is used in various applications. As a typical method for obtaining such a decorative molded product, there is an injection molding simultaneous decorating method as a method of laminating and integrating decorative sheets simultaneously with the molding of a resin molded product (Patent Document 1, Patent Document 2, etc.). reference).

Moreover, in the simultaneous injection molding decoration method, for example, in the case of providing a three-dimensional design feeling by providing an uneven pattern such as a wood grain conduit groove on the surface of a decorative molded product, for example, the following (1) to (4) I did it.
(1) A concavo-convex pattern for shaping is provided on the cavity surface of the injection mold, and the concavo-convex pattern is formed on the surface of the decorative molded product after injection molding (the surface of the decorative sheet).
(2) Using a resin sheet of a thermoplastic resin such as an acrylic resin for the base sheet of the decorative sheet, embossing to apply heat pressure to the base sheet and shaping the concavo-convex pattern Use a decorative sheet.
(3) The uneven pattern is expressed by screen printing or the like.
(4) A concavo-convex pattern is imparted to the decorative sheet by up-printing with an ink of a curable resin such as an ultraviolet curable resin. For example, an ionizing radiation curable resin ink is filled in at least a concave portion of a roll intaglio (also called a shaping plate, a molding plate cylinder, etc.) and a resin sheet is brought into contact with the ink. After the ink is cured by irradiating with ionizing radiation while being held in between, the resin sheet is peeled off from the roll intaglio to give an uneven pattern made of a cured product of the ink on the resin sheet ( (See Patent Literature 3, Patent Literature 4, Patent Literature 5, Patent Literature 6, etc.).

Japanese Patent Publication No. 50-19132 Japanese Patent Publication No.43-27488 JP-A-57-87318 Japanese Patent Publication No.57-22755 Japanese Examined Patent Publication No. 63-50066 JP 7-32476 A

However, the methods (1) to (4) have the following drawbacks. That is, in the method (1) of embossing at the time of injection molding of the molded product, the embossed surface is limited to the surface of the molded product. Therefore, it is not possible to give a concavo-convex pattern inside. Moreover, since it is necessary to make the cavity surface of the injection mold as a shaping mold, it is necessary to make it an uneven surface, so when changing the design of the uneven pattern, even if the shape of the molded product is the same, an expensive injection mold Everything had to be replaced, and the uneven pattern could not be changed freely.
Next, when a thermoplastic resin sheet is used for the base material sheet of (2), when decorating the decorative sheet in the vacuum forming process prior to the injection molding process, in order to decorate the three-dimensional surface of the molded product There was a problem that the uneven shape of the embossed uneven pattern was restored by the heat.
Next, in the case of forming a concavo-convex pattern by a printing method such as (3) screen printing, there is a limit to the amount of ink transferred, and since it is small, the three-dimensional effect cannot be obtained as much as the concavo-convex pattern by embossing.
And in the case of the build-up printing by the ultraviolet curable resin etc. which uses the roll intaglio etc. of (4), the uneven | corrugated pattern excellent in the three-dimensional effect can be shaped compared with the printing method of said (3). However, in general, in order to cure and form an uneven pattern by irradiating ultraviolet rays from the resin sheet side, the uneven pattern cannot be imparted unless a transparent sheet is used for the resin sheet. Moreover, when forming the decoration layer by normal printing on a decorating sheet, if a concavo-convex pattern was given before printing, the concavo-convex pattern was liable to cause a printing failure such as print omission during printing.

  That is, the subject of this invention is providing the decorating sheet which has the three-dimensional design feeling of an uneven | corrugated pattern. More preferably, even if the decorative sheet is thermoformed by vacuum forming or the like, it is to provide a decorative sheet in which the three-dimensional design feeling of the concavo-convex pattern expressed by the concavo-convex provided on the sheet surface and the inner surface is not easily lost. . Moreover, it is providing the decorative molded product using such a decorating sheet. Moreover, it is to provide an injection molding simultaneous decoration method by which such a decorative molded product can be easily obtained. Preliminary molding by the vacuum molding, and further, the uneven pattern at the decorative sheet stage even after the injection molding. It is to provide a decoration method in which the three-dimensional design feeling is not lost.

In order to solve the above problems, the decorative sheet of the present invention is formed by laminating a glitter layer on the back surface of a transparent resin base sheet, and the surface of the transparent resin base sheet is relatively glossy compared to the surroundings. The high-gloss area is divided into a high-gloss area and a low-gloss area where the gloss is relatively low compared to the surrounding area, and the transparent resin base sheet is relatively thick in the high-gloss area and low-gloss area. made is relatively thin at the, and the transparent resin substrate sheet, a first transparent resin substrate sheet which is positioned on the surface side, and two layers of the second transparent resin substrate sheet which is located on the back side The first transparent resin base sheet is made of a crystalline resin, the second transparent resin base sheet is made of an amorphous resin, and the melting point of the first transparent resin base sheet is the second transparent resin. It is higher than the softening temperature of the base sheet, high gloss area and low gloss It has a configuration that visually expressing the uneven pattern corresponding to the frequency.

In the above configuration, a glittering layer is laminated on the back surface of the transparent resin base sheet, and the surface of the transparent resin base sheet is relatively high in comparison with the high-gloss area having a relatively high gloss compared with the surroundings. In addition, it is divided into low gloss areas with low glossiness, and a structure that visually expresses uneven patterns corresponding to the high gloss areas and low gloss areas, and the thickness of the transparent resin base sheet is in the high gloss areas Is relatively thick and thinly formed in the low-gloss area. (Even if there are minute irregularities on the surface to achieve low gloss, Even on a flat surface (which does not exist), a three-dimensional design feeling that visually feels a concavo-convex pattern is obtained by the high and low gloss region of the surface and the concavo-convex portions in the sheet aligned with the surface .

Further, in the above configuration, the transparent resin substrate sheet is composed of a two-layer laminate of a first transparent resin substrate sheet located on the front surface side and a second transparent resin substrate sheet located on the back surface side, The first transparent resin base sheet is made of a crystalline resin, and the second transparent resin base sheet is made of an amorphous resin. The melting point of the first transparent resin base sheet is from the softening temperature of the second transparent resin base sheet. In the application where the decorative sheet is heat-molded, such as the simultaneous injection molding decoration method, the high-gloss area and the low-gloss area that are given as the presence or absence of surface irregularities are heat-molded. Both the contradictory conditions of prevention of disappearance and formability (or shape followability) of the decorative sheet can be easily achieved. The embossing is performed at a temperature equal to or higher than the melting point of the first transparent resin base material sheet, when the unevenness of the transparent resin base material sheet including minute unevenness is given by embossing, and the decorative sheet is This is because, when applied to a heat forming application such as vacuum forming, the maintenance of the unevenness and the moldability can be achieved at a temperature lower than the melting point and higher than the softening temperature of the second transparent resin base sheet. As a result, the visual three-dimensional design of the concavo-convex pattern involving the unevenness disappears even after the vacuum forming process of the decorative sheet and further after the injection molding process for the simultaneous injection molding decoration application. Not a decorative sheet .

Further, the decorative sheet of the present invention, in the above-mentioned construction, between the transparent resin substrate sheet and the brilliant layer, the full brilliance of the brilliant layer with a decorative layer so as not to conceal structure and did. By adopting such a configuration, a higher design can be achieved.

In addition, the decorative sheet of the present invention has a configuration in which a backing sheet made of a thermoplastic resin is laminated on the back surface of the glitter layer in any of the above configurations. By adopting such a configuration, if the total thickness of the decorative sheet as a whole is insufficient without a backing sheet in terms of application, formability, designability, etc., the decorative sheet I can cover the thickness. In addition, when the layer on the back side of the decorative sheet has insufficient adhesion to the resin molded article that is the adherend of the decorative sheet, the adhesion of the adherend to the resin molded article or the like The backing sheet can be made of a good resin to improve adhesion .

Moreover, the decorative sheet of the present invention has a configuration in which the portion corresponding to the high-gloss region on the surface of the transparent resin base material sheet is directed toward the back surface in the back surface of the transparent resin base material sheet. The configuration is convex . This configuration clearly shows an example of a specific configuration for making the thickness of the transparent resin base sheet relatively thicker in the high-gloss area on the surface than in the low-gloss area . By adopting such a configuration, even if the surface portion of the high-gloss area is convex toward the back surface, that is, the surface is concave toward the outside of the sheet, a three-dimensional design feeling that visually feels an uneven pattern can be obtained. .

  The decorative molded product of the present invention has a configuration in which the decorative sheet having any one of the above-described structures is laminated on the surface of the resin molded product so that the transparent resin base sheet side is positioned on the surface side. . By adopting such a configuration, in each configuration of the decorative molded product with the resin molded product as an adherend, each of the above-mentioned three-dimensional design feelings that make the uneven pattern visually felt can be obtained. An effect is obtained.

  Further, the decorative molded product of the present invention has the above-described configuration, and in the high gloss region of the transparent resin base sheet of the decorative sheet portion, the back side (of the transparent resin base sheet) is in the back direction. It has a configuration in which the surface is convex and the surface side is a flat surface. This configuration clearly shows an example of a specific configuration for making the thickness of the transparent resin base sheet in the decorative sheet portion relatively thicker in the high-gloss area on the surface than in the low-gloss area. . With this configuration, the surface portion of the high gloss region has a flat shape, and a three-dimensional design feeling that makes the concavo-convex pattern feel visually is obtained.

  Alternatively, the decorative molded product of the present invention is the above-described configuration, wherein the back surface side (of the transparent resin substrate sheet) is the back surface direction in the high gloss region of the transparent resin substrate sheet of the decorative sheet portion. And the surface side is concave toward the surface direction. This configuration is also a configuration that clearly shows an example of a specific configuration for making the thickness of the transparent resin substrate sheet in the decorative sheet portion relatively thicker in the high-gloss area on the surface than in the low-gloss area. . In such a configuration, the shape of the surface area of the high-gloss area that is actually recessed toward the outside of the sheet, combined with the quasi-concave feeling due to the visual effect, creates a three-dimensional design feeling that makes the concavo-convex pattern feel visually. Is obtained.

And the injection molding simultaneous decorating method of the present invention uses a decorative sheet, passes through a vacuum forming step and an injection molding step, and integrates the decorative sheet on the surface simultaneously with the molding of the resin molded product, In the injection molding simultaneous decorating method using a resin molded product as a decorative molded product, at least,
(A) A laminated body including a transparent resin substrate sheet and a glitter layer is heated, and embossing is performed to obtain a high gloss region and a low gloss region on the surface of the transparent resin substrate sheet, and the high gloss region and the low gloss region. To produce a decorative sheet of any of the above-mentioned structures by forming a thin thickness of the transparent resin substrate sheet corresponding to
(B) Vacuum forming step of heat-softening the decorative sheet and vacuum forming into a shape corresponding to a desired molded product shape,
(C) A resin in a fluid state is placed in the injection mold in a state where the vacuum-formed decorative sheet is loaded in the clamped injection mold so that the surface side faces the injection mold surface. Injection filling, solidifying the resin, laminating and integrating a decorative sheet on the surface of the resin molded product, to obtain a decorative molded product having any one of the above-described configurations, each step of the injection molding step in this order. I tried to do it.

  By adopting such a decoration method, the effects of each of the decoration sheets, such as the ability to give a three-dimensional design that makes the uneven pattern visually feel, can be enjoyed in the injection molding simultaneous decoration method. The effect can be enjoyed in the decorative molded product obtained.

  Moreover, the injection molding simultaneous decorating method of the present invention is the decorating method of the above configuration, wherein the transparent resin base sheet is positioned on the surface side as the decorating sheet in the sheet creating step of the step (A). A temperature equal to or higher than the melting point of the first transparent resin base sheet, using the decorative sheet composed of a two-layer laminate of the first transparent resin base sheet and the second transparent resin base sheet positioned on the back side. In the vacuum forming step of step (B), vacuum forming is performed at a temperature that is equal to or higher than the softening temperature of the second transparent resin base sheet and lower than the melting point of the first transparent resin base sheet. did.

  By setting it as the decorating method of such a structure, the effect by the said decorating sheet in which a transparent resin base material sheet consists of a specific 2 layer laminated body is ensured, and the injection molding simultaneous decorating method (and the decoration obtained by it) It can be enjoyed in decorative molded products). Therefore, even after the vacuum forming step and further the injection molding step, a decorative molded product that does not lose the visual three-dimensional design feeling of the uneven pattern at the decorative sheet stage can be obtained with certainty.

  According to the decorative sheet of the present invention, even when the surface is flat, it is possible to obtain a three-dimensional design feeling that visually gives an uneven pattern. Moreover, if it is set as the structure by which the decoration layer was provided between the transparent resin base material sheet / glittering layers, it can be made a higher design. Moreover, if it is set as the structure which provided the backing sheet in the glittering layer back surface, the ensuring of the total thickness of a decorating sheet, the adhesive improvement with adherends, such as a resin molding, etc. can be aimed at. Moreover, if the transparent resin base material sheet back surface corresponding to the high gloss region on the front surface is configured to be convex in the back surface direction (because the sheet thickness of that portion is relatively thicker than other portions), Even if the surface is convex, it is possible to obtain a three-dimensional design feeling that visually gives an uneven pattern.

  Moreover, according to the decorative molded product of this invention, each effect of the said decorating sheet, such as the three-dimensional design feeling which makes a concavo-convex pattern feel visually, is acquired.

  In addition, according to the injection molding simultaneous decorating method of the present invention, the respective effects of each of the decorative sheets such as providing a three-dimensional design feeling that makes the uneven pattern visually feel can be achieved in the injection molding simultaneous decorating method. Can be obtained. Furthermore, in that case, if the transparent resin base sheet is a specific two-layer laminate for the decorative sheet to be used, the visual three-dimensional design feeling of the uneven pattern at the decorative sheet stage is vacuum formed. Even after the process, and even after the injection molding process, it can be reliably applied to the decorative molded product so as not to disappear.

Sectional drawing which illustrates some example forms of the decorating sheet of this invention. Sectional drawing which illustrates another example of a form of the decorating sheet of this invention. Sectional drawing which illustrates another example of a form of the decorating sheet of this invention. Sectional drawing which illustrates an example with a certain form of the decorative molded product of this invention. Sectional drawing explaining one method (embossing method) which forms the high / low glossiness area | region of the transparent resin base material sheet surface, and forms the convex part of the back surface position-synchronized with this. The conceptual diagram explaining the injection molding simultaneous decorating method which can be utilized by this invention with the form.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

Overview:
Drawing 1 is a sectional view which illustrated three examples of the basic composition about decorating sheet S of the present invention. In addition, the decorative sheets Sn (n is an integer) such as the decorative sheets S1, S2, S3, or S4 in various forms are collectively referred to simply as the decorative sheet S.

  First, the decorative sheet S1 shown in FIG. 1 (A) is provided with a glittering layer 2 on the back surface of the transparent resin base sheet 1 (laminated), and the surface of the transparent resin base sheet 1 is relatively surrounding. It is divided into a low gloss region L having a lower gloss (for example, matte) and a high gloss region H (Hf) having a relatively higher gloss (for example, gloss) than the surroundings. In the case of FIG. 1A, the surface of the high gloss region H is a flat surface, which is represented as the high gloss region Hf. Furthermore, the thickness of the transparent resin base sheet 1 is relatively thicker in the high gloss region Hf and thinner in the low gloss region L. In addition, in the high gloss region Hf, the back surface of the transparent resin base sheet 1 protrudes toward the back surface (depresses toward the surface), and a protruding portion p is formed.

  Further, the surface of the transparent resin base sheet 1 is flat in the low gloss region L. On the other hand, in the high gloss region H, there are three types as shown in the sectional views of FIG. That is, when flat as shown in FIG. 1A (high gloss region Hf), when concave as shown in FIG. 1B (high gloss region Hr), or FIG. 1C. This is a case where a convex shape is formed (high gloss region Hp). In the present invention, these high gloss areas Hf, Hr, and Hp are collectively referred to as high gloss areas H.

  In addition, the meaning of “front surface” and “rear surface” in this specification means “front surface” means the transparent resin base material sheet 1 side direction of the decorative sheet S (observer side direction of the decorative sheet). means. In the drawings such as FIG. 1, the upper side is the surface side. On the other hand, the “back surface” means the direction of the glittering layer 2 side of the decorative sheet (the direction opposite to the observer side of the decorative sheet, which is also the adherend direction). In the drawings such as FIG. 1, the lower side is the back side.

  In addition, the decorative sheet of the present invention can further form a decorative layer 3 between the transparent resin base sheet 1 and the glitter layer 2 as shown in FIG. The backing sheet 4 can be provided on the back surface, or an adhesive layer can be provided on the back surface to provide adhesion to the adherend although not shown. The decorative layer 3, the backing sheet 4, and the adhesive layer are basically layers provided as necessary, and these are formed by any one layer or a combination of any two layers. I can do it.

  And if the decorative sheet S as described above is laminated on the surface of the resin molded product 5 by various lamination methods for the adherend, for example, the injection molding simultaneous decoration method, etc., the decorative molded product Pd of the present invention and (See FIG. 4). Moreover, as a suitable lamination method, there is the injection molding simultaneous decorating method of the present invention. Moreover, in the injection molding simultaneous decorating method, the embossing process is performed at the stage of creating the decorating sheet, in which the transparent resin base sheet is a specific two-layer laminate. It is more preferable in that the visual three-dimensional design feeling of the uneven pattern used can be surely imparted to the decorative molded product so as not to disappear even after the vacuum molding step and further the injection molding step. In that case, more preferably, the decorative sheet is embossed at the time of creating it at a melting point of the first transparent resin base sheet or more in terms of achieving both the reliable provision of the uneven pattern and the decorative sheet formability. The sheet is used, and at the time of the vacuum molding step of simultaneous injection molding, it is performed at a temperature not lower than the softening temperature of the second transparent resin base sheet and lower than the melting point of the first transparent resin base sheet.

Decorative sheet:
First, the configuration of the decorative sheet will be described.

[Transparent resin base sheet]
Material: As a material of the transparent resin base sheet 1, the embossing suitability for imparting transparency, a high gloss region, a low gloss region, and a thickness of the sheet thickness from among transparent thermoplastic resins, When the decorative sheet is heat-softened and subjected to molding such as vacuum molding, the compatibility of the molding suitability by heat during the molding and the durability of embossing (preventing the loss of embossing) is taken into consideration. Select.

  Examples of the material of the thermoplastic resin as described above include polyethylene resins such as polyethylene, polypropylene, polymethylpentene, polybutene, and olefin-based thermoplastic elastomer, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, terephthalic acid- Polyester resin such as isophthalic acid-ethylene glycol copolymer, terephthalic acid-ethylene glycol-1,4 cyclohexanedimethanol copolymer, polyester-based thermal plastic elastomer, polyamide resin such as nylon 6, nylon 9, nylon 6,6 , Fluorinated resins such as polyvinyl fluoride, polyvinylidene fluoride, poly (vinylidene fluoride), ethylene-tetrafluoroethylene copolymer, poly (tetrafluoroethylene), acrylic resins, polyvinyl chloride, Polystyrene, polycarbonate resins, and the like.

  Examples of the acrylic resin include polymethyl (meth) acrylate, polyethyl (meth) acrylate, polybutyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymer, and ethyl (meth) acrylate- Resins such as butyl (meth) acrylate copolymer and methyl (meth) acrylate-styrene copolymer (however, (meth) acrylate means acrylate or methacrylate) are used alone or in a mixture of two or more.

  Thickness: The thickness of the transparent resin base sheet (total thickness in the case of a laminate structure) is about 50 to 400 μm.

  Additive: Further, an additive can be appropriately added to the transparent resin substrate sheet as necessary. Appropriate amounts of various additives can be added as long as they do not hinder the thermal behavior such as transparency, surface gloss, and melting point. For example, UV stabilizers such as benzotriazole and benzophenone, light stabilizers such as hindered amine radical scavengers, lubricants such as silicone resins and waxes, colorants, plasticizers, heat stabilizers, antibacterial agents, antifungal agents , Antistatic agents and the like.

  Layer structure: The layer structure of the transparent resin substrate sheet may be a single layer or a laminate in which two or more layers of different kinds of resins are stacked. However, when the decorative sheet is applied to a heat forming process such as vacuum forming or a method of simultaneous injection molding in a mold, the transparent resin base sheet 1 has a moldability of the transparent resin base sheet itself. Both the contradictory conditions of (or shape following) and prevention of disappearance of the high gloss region and the low gloss region provided as the presence or absence of minute irregularities on the surface must be made compatible.

  The above-mentioned compatibility can be solved by shaping conditions, adjustment of molding conditions, selection of resin materials, etc., but as a preferable form that can stably satisfy both conditions, a transparent resin group is used as shown in FIG. The material sheet 1 is a two-layer laminate of a first transparent resin base sheet 11 located on the front side and a second transparent resin base sheet 12 located on the back side, and the first transparent resin base sheet 11 is A crystalline resin having a melting point is used, and the second transparent resin base sheet 12 is an amorphous resin having no melting point. Moreover, the melting point of the first transparent resin base sheet is set higher than the softening temperature of the second transparent resin base sheet. In addition, as a softening temperature, VICAT softening temperature (standard DIN-ENTW.53,460 regulation) is used as an index.

  By forming a transparent resin base sheet of a two-layer laminate having specific temperature properties as described above, when forming surface irregularities by embossing, it must also be carefully crushed by heating, especially with minute irregularities When attention is paid to the unevenness related to the gloss on the surface side, the crystalline resin of the first transparent resin substrate sheet is melted by embossing at a temperature higher than the melting point of the first transparent resin substrate sheet. However, when the temperature drops after embossing, the resin recrystallizes and the uneven shape is fixed, and the decorative sheet is again used during heat molding such as vacuum molding for simultaneous injection molding. When heating, if the temperature is lower than the melting point (and not less than the VICAT softening temperature of the second transparent resin base sheet), the crystal structure is maintained. While ensuring the second transparent resin substrate sheet mainly to the shape of the fine irregularities is being easily maintained. Furthermore, for the unevenness on the back side of the second transparent resin base sheet, the decorative sheet is attached to the adherend itself, or an adhesive for adhering to the adherend, while these are in a fluid state, By burying the irregularities on the back side of the decorative sheet, the irregularities on the back side can be retained. For example, in the case of decorating a decorative sheet simultaneously through injection molding through a vacuum forming step, first, when the decorative sheet is preformed into a molded product shape by vacuum forming, usually the surface of the decorative sheet Although the side is pressed against the vacuum mold side, since the unevenness on the back side is in a free state, the disappearance of the unevenness on the back side can be prevented. Next, in the injection mold, the decorative sheet is pressed on the surface of the injection mold, but the back side unevenness is filled with the injection resin in a fluid state, so the back side unevenness is resin molded. Retained in the object.

  Specifically, the combination of the first transparent resin base sheet and the second transparent resin base sheet as described above is added to the decorative sheet in the case of vacuum forming as preforming in the simultaneous injection molding method. Since the temperature is in the range of 100 to 170 ° C., the second transparent resin base sheet 12 includes acrylic resin (in the case of polymethyl (meth) acrylate, VICAT softening temperature 120 ° C.), polycarbonate resin (VICAT softening temperature 155 ° C. ) Or polystyrene (VICAT softening temperature 103 ° C.), etc., and the first transparent resin base sheet 11 is made of polyvinylidene fluoride (melting point 160 ° C. or higher), polytetrafluoroethylene (melting point 327 ° C.), poly 3 fluorine. If a fluorine-based resin such as ethylene fluoride (melting point: 205 to 220 ° C.) is used, the embossing temperature is equal to or higher than the melting point of the first transparent resin substrate sheet 11. In performed, the vacuum molding temperature below the melting point of the first transparent resin substrate sheet 11, it is possible to select the combination and a softening temperature or higher of the second transparent resin substrate sheet 12.

  In addition, as a specific combination example of the resin of the two-layer laminate of the first and second transparent resin base sheets, a fluorine-based resin (more specifically, for example, vinylidene fluoride resin) is used as the first transparent resin group. A configuration in which the acrylic resin is used for the material sheet and the acrylic resin is used for the second transparent resin base sheet is one of preferable configurations. Among the fluorine-based resins, in particular, vinylidene fluoride resin is preferable from the viewpoint of an appropriate melting point and the like that are not too high and too low in terms of cost. On the other hand, an acrylic resin is preferred because it tends to widen the molding suitability temperature range at the time of heating the sheet, and is also preferred in terms of excellent weather resistance and transparency.

  By the way, as a detail of the heating temperature of the decorative sheet at the time of vacuum forming (including vacuum / pressure forming) as a preliminary forming of the simultaneous injection molding method, the vacuum forming die is also used as the injection forming die. In the case of in-line preforming performed on an injection mold, the temperature is about 100 to 120 ° C., and vacuum molding is performed separately from the injection mold, that is, in the case of offline preforming performed in advance outside the injection molding machine. Is 140-170 ° C. Therefore, from these viewpoints, the resin of the first transparent resin substrate sheet has a melting point of 120 ° C. or higher, preferably 130 ° C. or higher if limited to in-line preforming, and 150 ° C. if offline pre-molding is considered. As described above, it is preferable to select a resin having a temperature of 170 ° C. or higher.

  In addition, what is necessary is just to let the thickness of a 1st transparent resin base material sheet be a thing according to the depth of the uneven | corrugated shape for making the surface low gloss. In addition, the vacuum formability as the whole decorative sheet can be mainly borne by other layers such as the second transparent resin base sheet. Therefore, the thickness of the first transparent resin base sheet is usually made thinner than the thickness of the second transparent resin base sheet. If the specific example of the thickness of a 1st transparent resin base material sheet is given, it will be about 10-50 micrometers.

  On the other hand, the 2nd transparent resin base material sheet is a layer for ensuring the vacuum formability as a decorating sheet, and taking out the unevenness | corrugation of the transparent resin base material sheet back side. Moreover, normally, it is set as the layer which bears the total thickness as a decorating sheet mainly rather than a 1st transparent resin base material sheet. Therefore, a resin having better vacuum formability than the first transparent resin substrate sheet is used for the second transparent resin substrate sheet. In these respects, the thickness of the second transparent resin base sheet is usually thicker than the thickness of the first transparent resin base sheet. For example, if the specific example of the thickness of a 2nd transparent resin base material sheet is given, it will be about 50-200 micrometers. In addition, the thickness relationship between the thickness of the first transparent resin substrate sheet and the second transparent resin substrate sheet is not limited to this.

In addition, lamination | stacking with a 1st transparent resin base material sheet and a 2nd transparent resin base material sheet may prepare these each layer as a resin sheet, and may laminate | stack both resin sheets through an adhesive agent, but productivity, In terms of cost and the like, it is preferable to prepare melt lamination by two-layer coextrusion of both resins, or to prepare one as a resin sheet and apply melt extrusion coating thereto. In the two-layer coextrusion or melt extrusion coating, there is an advantage that a thin resin layer that cannot be formed as a resin sheet can be formed. Among these, two-layer coextrusion is more preferable in terms of interlayer adhesion of the laminated sheet.
High-gloss area and low-gloss area: In the present invention, the high-gloss area L and the low-gloss area H are two areas having relatively different gloss in terms of the gloss of the surface of the transparent resin substrate sheet 1. A visual unevenness due to the thickness of the transparent resin substrate sheet 1 and the back surface unevenness of the light-reflective interface between the transparent resin substrate sheet 1 and the glittering layer 2 by the regions H and L. Has the function of reinforcing.

  A pattern composed of a high-gloss area H and a low-gloss area L (this pattern is called a concavo-convex pattern because it has a visual concavo-convex sensation), according to the required design expression. There is no particular limitation. The uneven pattern is, for example, a wood grain conduit groove, a wood grain annual ring pattern, a sand grain, a satin, a hairline, a line groove, an irregular pattern on a granite cleaved surface, a textured surface texture, a skin draw, a character, a geometric pattern, etc. . In particular, a region where the concave portion is visually expressed is made to correspond to the high gloss portion H, and a region where the convex portion is visually expressed is made to correspond to the low gloss region L. Conventionally, there is a known technology that makes the surface appear to have a concavo-convex pattern due to the gloss pattern on the surface. As in the present invention, since the visual interaction between the glitter layer on the back surface of the transparent resin base sheet and the thickness difference between the transparent resin base sheets is not used, the mechanism of action is different from that of the present invention. As a result, the high gloss region H corresponds to the convex portion and the low gloss region L corresponds to the concave portion, and the gloss level is completely opposite to the present invention.

  The gloss difference between the high gloss region H and the low gloss region L may be such that the gloss difference can be recognized visually. Usually, the 60 degree specular gloss Gs (60 °) specified in JIS Z8741 is 5 or more, more preferably 20 or more. The low gloss region L has a relatively rough surface by forming minute irregularities than the high gloss region H, and the high gloss region H has relatively higher surface smoothness than the low gloss region L. For example, in the high gloss region H, for example, the surface roughness of the surface of the transparent resin base sheet 1 is such that the center line average roughness Ra specified in JIS B0601 is less than 1 μm and the specular gloss Gs ( 60 °) is 80 or more, and in the low gloss region L, the center line average roughness Ra of the surface of the transparent resin substrate sheet 1 is 4 μm or more and the specular gloss Gs (60 °) is 40 or less. To do.

  In addition, formation of the above-mentioned difference in the degree of fine unevenness (rough surface) for producing a gloss difference can be formed by a known method, for example, embossing.

  Thickness difference: The thickness of the transparent resin base sheet 1 is formed so as to be relatively thick in the high gloss region H and thin in the low gloss region L. The difference in thickness is usually about 10 to 100 μm. In the thick film portion immediately below the high gloss region H, as shown in FIG. 1, the interface between the transparent resin base sheet 1 and the glittering layer 2 (also referred to as a light reflective interface) protrudes in the back surface direction ( It is shaped so as to form a protruding portion p. The shape of the protruding portion p is preferably a curve that has at least a cross-sectional shape protruding in the back surface direction. For example, a circle, an ellipse, a parabola, a hyperbola, a sine curve, an elliptic function curve, a Bessel function curve, a cycloid, etc., or a curve approximated by these. The vertical cross-sectional shape may be a curve that is convex in the back surface direction, or may be another shape such as a straight line that is convex in the back surface direction. By projecting the light-reflective interface in such a shape in the direction of the back surface, the light-reflective interface functions like a concave mirror, and once the illumination light is converged to the focal point (focal line) Diverge from there. Therefore, the depth and shape of the protruding portion p appear to be emphasized brighter. In addition to this, a shadow is generated on the side surface of the protruding portion p with respect to the illumination light incident from the oblique direction, and the contour of the protruding portion is emphasized (edge enhancement). Furthermore, the depth and shape of the protruding portion (indented portion when viewed from the surface) are set to be higher than the surrounding by setting the upper portion of the protruding portion as the high gloss region H and surrounding the relatively low gloss region L. The effect to emphasize is also added. As a result, even if the surface of the transparent resin substrate sheet 1 is flat or slightly protruded, a sufficient unevenness is visually reproduced.

  Method of forming high and low gloss regions and back surface protruding portion: forming high gloss region H and low gloss region L as described above on back surface of transparent resin base sheet 1 and back surface protruding portion p aligned with the high gloss region H. As a method, a conventionally known shaping method such as an embossing method may be appropriately employed. However, as described above, as the transparent resin base sheet, the transparent resin base sheet is composed of the first transparent resin base sheet of crystalline resin and the second transparent resin base sheet of amorphous resin, and the first When using a sheet having a two-layer laminate in which the melting point of the transparent resin substrate sheet is larger than the softening temperature of the second transparent resin substrate sheet, generally, the embossing temperature of the first transparent resin substrate sheet 11 is used. Becomes higher than the melting temperature of the second transparent resin substrate sheet 12. In that case, both transparent resin base material sheets will be in a fluid state. In order to perform embossing under such circumstances, for example, the following processing methods (A) and (B) are possible. Moreover, the processing method of (C) etc. are possible for heating a 1st transparent resin base material sheet more than the melting | fusing point and heating a 2nd transparent resin base material sheet below its melting temperature, and embossing. The embossing method and machine itself are known.

(A) Both transparent resin base material sheets are used as a single wafer sheet, and this is embossed with a single wafer heat press.
(B) Both transparent resin base sheets are made into continuous belt-like sheets, which are sandwiched and pressed between an endless belt-like embossed plate and an endless belt-like impression cylinder, and both endless belts are synchronized with the sheet running speed. By driving, embossing is performed without substantially applying tension to the two transparent resin substrate sheets in a fluidized state.
(C) Both transparent resin base material sheets are made into a continuous belt-like sheet, and this is embossed using a rotary embossing machine in a laminated state. However, the second transparent resin base sheet 12 side is heated below the melting temperature of the second transparent resin base sheet 12 by heat conduction from the heating drum, while the first transparent resin base sheet 11 side is infrared. Only the first transparent resin base sheet 11 near the surface is locally heated by the radiation heater so as to be equal to or higher than the melting point of the first transparent resin base sheet 11 and embossed.

  Furthermore, one preferred method for forming the two-layer laminate structure will be described with reference to FIG.

  First, the 1st transparent resin base material sheet 11, the 2nd transparent resin base material sheet 12, and the glittering layer 2 which are all flat uniform film thickness are prepared. In this figure, the first transparent resin substrate sheet 11 on the front surface side and the second transparent resin substrate sheet 12 on the rear surface side are laminated in advance, and printing is performed on the back surface of the second transparent resin substrate sheet 12. The glittering layer is also laminated by the method or the like, but all three layers may be prepared as separate layers and laminated simultaneously with embossing. The first resin base sheet 11 is made of a crystalline resin, the second transparent resin base sheet 12 is made of an amorphous resin, and the melting point of the first transparent resin base sheet 11 is that of the second transparent resin base sheet 12. It is chosen to be greater than the softening temperature.

  Next, each layer is inserted between the rubber impression cylinder C and the metal embossed plate E as shown in FIG. The surface of the rubber impression cylinder C is a rough surface Fr corresponding to the rough surface to be shaped on the surface of the first transparent resin base sheet 11. The rubber impression cylinder C has at least a surface made of rubber such as silicone rubber, but the center portion may be made of a rigid core material such as iron. The metal embossed plate E is made of a metal such as iron or copper, and has an uneven surface corresponding to the unevenness to be formed on the back surface of the second transparent resin base sheet 12 on the surface. The rubber impression cylinder C and the metal embossed plate E may be flat or cylindrical.

  And the 1st transparent resin base material sheet 11, the 2nd transparent resin base material sheet 12, and the glittering layer 2 are heat-softened, and the surface side of the 1st transparent resin base material sheet 11 is as shown in FIG.5 (B). The rubber impression cylinder C and the metal embossing plate E are pressed in a positional relationship where they contact the rubber impression cylinder C side and the back side of the glitter layer 2 contacts the metal embossing plate E side (so-called embossing). During the heating, the surface side of the first transparent resin substrate sheet 11 is heated by an infrared radiation heater (not shown), and the vicinity of the surface of the first transparent resin substrate sheet 11 is heated to the melting point or higher. On the other hand, the second transparent resin substrate sheet 12 side is heated by heat conduction from a heating drum (not shown), and the second transparent resin substrate sheet 12 is heated so as not to reach the melting temperature.

  As shown in FIG. 5B, in embossing, in the high embossing pressure region B pressed by the convex part ep of the metal embossing plate E, each layer is strongly pressed, and both transparent resin base sheets 11 and 12 are pressed. Is relatively thin. At the same time, the rough surface Fr on the surface of the rubber impression cylinder C is completely shaped, and the surface of the first transparent resin base sheet 11 becomes a low gloss region L. On the other hand, in the low embossing pressure region A pressed by the recess er of the metal embossed plate E, the pressing is weak in each layer, and the thickness of both transparent resin base sheets 11 and 12 is relatively thick. At the same time, the shaping of the rough surface Fr on the surface of the rubber impression cylinder C becomes incomplete, and the surface of the first transparent resin base sheet 11 becomes a high gloss region H. Then, after each layer is cooled or before cooling, the rubber impression cylinder C and the metal embossed plate E are released from pressing, and each layer is laminated and shaped, and the decorative sheet of the present invention as shown in FIG. S5 is obtained.

(Brightness layer)
The glitter layer 2 is provided (laminated) on the back surface of the transparent resin substrate sheet 1. The material of the glitter layer, the formation method, and the like may be conventionally known ones. For example, the glitter layer may be a glitter ink layer in which a glitter pigment is dispersed in a transparent binder (binder), a metal thin film layer, or the like. As the resin for the binder of the glitter ink layer, acrylic resin, vinyl chloride-vinyl acetate copolymer, chlorinated polypropylene, polyester resin, polyurethane resin, or the like is used. As the bright pigment, metal powder such as aluminum or brass or metal pigment such as scale, pearlescent pigment such as titanium dioxide-coated mica powder or scale, or the like is used. Further, the glittering ink layer may be formed by a coating method such as roll coating, comma coating, slit reverse coating, curtain flow coating, etc., full surface printing by gravure printing, silk screen printing, or the like. Moreover, it is good also as coloring metallic luster (color metallic) by adding coloring agents, such as a coloring pigment, other than a luster pigment. The thickness of the glitter ink layer is usually about 1 to 50 μm. On the other hand, as the metal thin film layer, for example, a metal such as aluminum, chromium, tin, or indium may be deposited, sputtered, electroless plated, or the like. In addition, a coloring agent is added to the transparent resin base sheet 1 or a colored transparent ink layer is provided between the transparent resin base sheet 1 and the metal thin film layer, so that the glitter metal by the glitter layer is also colored. It may be glossy (color metallic). In addition, the thickness of a metal thin film layer is about 0.1-1 micrometer normally.

[Decoration layer]
The decorative layer 3 is a layer provided as necessary in order to obtain a higher design. The decorative layer is partially provided or formed of a transparent material such as transparent colored ink so as not to hinder the glitter of the glitter layer 2 and the visual unevenness based thereon. The ink used for forming the decorative layer may be appropriately selected from known ones. For example, an acrylic resin, vinyl chloride-vinyl acetate copolymer, chlorinated polypropylene, polyester resin, polyurethane resin, or the like is used as the resin for the ink binder. Examples of the colorant contained in the ink include titanium white, zinc white, carbon black, iron black, petal, cadmium red, ultramarine, cobalt blue, yellow lead, titanium yellow, and other inorganic pigments, phthalocyanine blue, and indus. Organic pigments such as ren blue, isoindolinone yellow, quinacridone red, and perylene red, or dyes are used. The decorative layer pattern is, for example, a wood grain pattern, a stone pattern, a grain pattern, a texture pattern, a leather pattern, a tiled pattern, a brickwork pattern, a geometric figure, a character, a symbol, or a solid surface. . Moreover, as a decoration layer, functional layers, such as a magnetic body layer and an electroconductive layer, etc. other than expression of pattern designs, such as a grain, may be sufficient. In other words, decoration or decoration includes such functionality.

[Backing sheet]
The backing sheet 4 is provided as appropriate mainly for adjusting (securing) the total thickness as a decorative sheet. The backing sheet 4 can also be provided in order to improve the adhesion with the adherend. Such a backing sheet 4 can be formed by laminating a thermoplastic resin sheet on the back side of the glittering layer. Examples of the thermoplastic resin include various polyolefin resins such as polypropylene, chlorinated polyolefin resins, ABS resins, or mixed resins of different resins and mixed resins of polyolefin resins and ABS resins, for example. What is necessary is just to employ | adopt suitably according to material etc. In particular, when vacuum-decorating a decorative sheet, a transparent resin base sheet, and if it is a two-layer laminate, the same resin as the second transparent resin base sheet so as not to impair the moldability It is preferable to comprise.

  In order to laminate the backing sheet, a resin sheet prepared in advance as a thermoplastic resin sheet may be bonded with a known adhesive such as a urethane resin by a known lamination method such as a dry lamination method. Specifically, for example, a thermoplastic resin sheet is bonded to the glitter layer surface of the laminate of the transparent resin base sheet and the glitter layer with an adhesive. The thermoplastic resin sheet of the backing sheet may be laminated simultaneously with film formation by melt extrusion coating of the thermoplastic resin. The thickness of the backing sheet is usually about 20 to 500 μm in terms of ensuring the total thickness although it depends on the purpose such as ensuring the total thickness and improving the adhesion to the adherend.

  Further, the backing sheet can also serve as a concealing reinforcing function that conceals the adherend. If the glittering layer is a thin film and the above concealing property is insufficient, or when a decorative sheet is formed, the glittering layer is partially stretched to become a thin film or cracked, resulting in concealment. May decrease. This can be supplemented with a backing sheet. In order to make the backing sheet concealable, a highly concealable pigment may be added to the thermoplastic resin in order to impart concealability. Examples of the high hiding pigment include titanium white and carbon black (black). In this case, if necessary, other colorants may be added appropriately.

  In addition, a well-known adhesive layer can be suitably provided in the outermost back surface of a decorating sheet irrespective of the presence or absence of a backing sheet. For the adhesive layer, for example, acrylic resin, vinyl chloride-vinyl acetate copolymer, chlorinated polyolefin resin, urethane resin, rubber resin, and the like are used.

[Adherence of decorative sheet]
The decorating sheet of the present invention can be used for the purpose of laminating and decorating various adherends, but the adherend is not particularly limited. For example, the material and shape of the adherend are arbitrary. Examples of the material include resin, wood material, metal, non-metallic inorganic material, paper, and fabric. Moreover, the shape is arbitrary with a sheet | seat (or film), a board, a solid thing, etc.

Decorative molded products:
The decorative molded product of the present invention has a structure in which the decorative sheet of the present invention is laminated on the surface of a resin molding as an adherend so that the transparent resin base sheet side is positioned on the surface side. It is a decorative molded product. At that time, in the high gloss region of the decorative sheet portion, for example, the back surface side of the transparent resin base material sheet is convex toward the back surface direction, and the surface side of the portion is a flat surface, For example, the shape is concave toward the surface.

  In the decorative sheet itself, the adherend is not particularly limited. However, in terms of the effect of the decorative sheet, a preferred adherend and a method of laminating the adherend are: The adhering body is a resin molded product, and the lamination method is that the decorative sheet is preformed on the surface of the resin molded product by vacuum forming into a desired molded product shape and then applied to the surface of the resin molded product in an injection mold. In this case, the decorative sheets are laminated and integrated using a so-called injection molding simultaneous decorating method. In this case, the decorative sheet of the present invention exhibits a three-dimensional design feeling of the uneven pattern with a visual effect even if the sheet surface is flat or substantially flat. There is no risk of the concavo-convex shape disappearing, and a good concavo-convex pattern can be visually imparted.

  The above-described effects are particularly favorably achieved by the transparent resin substrate sheet 1 having the first transparent resin substrate sheet 11 positioned on the front surface side and the second transparent resin substrate sheet 12 positioned on the back surface side. It is composed of a two-layer laminate, the first transparent resin base sheet is composed of a crystalline resin, the second transparent resin base sheet is composed of an amorphous resin, and the melting point of the first transparent resin base sheet is This is a case where a decorative sheet having a configuration configured to be higher than the softening temperature of the second transparent resin base sheet is employed.

  Here, an example of a decorative molded product Pd having a structure in which the resin molded product 5 is used as an adherend and the decorative sheet S of the present invention as described above is laminated on the surface thereof, is partially cut away in FIG. A cross-sectional view and a partially enlarged view of the cross-section are shown in FIG. One of the typical methods for producing such a decorative molded product is an injection molding simultaneous decoration method. In addition, in FIG. 4 (B), the transparent resin base material sheet 1 is a case of the 2 layer laminated body structure of the 1st transparent resin base material sheet 11 and the 2nd transparent resin base material sheet 12. FIG. In addition, the shape of the decorative molded product is a non-planar surface such as a concavo-convex surface or a planar solid object. Further, the shape of the decorative molded product is arbitrary such as a plate shape (a flat plate, a curved plate, etc.), a columnar shape, a three-dimensional solid object, and the like.

  In addition, as injection resin used as a resin molding, there is no restriction | limiting in particular fundamentally and well-known resin may be sufficient. 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, styrene resin, acrylic resin, vinyl chloride resin, polycarbonate 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. In addition, the injection resin contains various known additives such as colorants, fillers, stabilizers, lubricants, and the like as appropriate according to the application.

Injection molding simultaneous decoration method:
In the injection molding simultaneous decorating method according to the present invention, the so-called injection molding simultaneous decorating method is a specific step for the sheet creating process (sheet material and method) of the decorating sheet used therein, and even more preferably, The vacuum forming process as the preforming of the sheet is also a decorating method with a specific process. Hereinafter, the present injection molding simultaneous decorating method will be described in the order of a sheet creation process, a vacuum molding process, and an injection molding process.

[Sheet creation process]
The sheet creation process is a process for preparing and preparing a decorative sheet as described above. Therefore, the sheet creation process according to the present invention is a sheet creation process in which the decorative sheet layer and its resin composition, melting point, softening temperature, embossing temperature for uneven shaping are specified. That is, in the sheet preparation process, as a decorative sheet, a laminate including at least a transparent resin base sheet and a glittering layer positioned outside in the state of a decorative molded product is heated and embossed to obtain a transparent resin base material. A decorative sheet is prepared by forming a high-gloss area and a low-gloss area on the surface of the sheet, and a transparent resin base material sheet corresponding to the high-gloss area and the low-gloss area. In that case, more preferably, as a configuration to be combined with a specific vacuum forming step later, the transparent resin base sheet is a first transparent resin base sheet located on the front side, and a second transparent resin base located on the back side. The first transparent resin base sheet is made of a crystalline resin, the second transparent resin base sheet is made of an amorphous resin, and the melting point of the first transparent resin base sheet Prepares a decorative sheet having a specific two-layer laminate structure in which the transparent resin base sheet is higher than the softening temperature of the second transparent resin base sheet. In addition, if the suitable specific example of this decorating sheet is given, as above-mentioned, it is the structure in which a 1st transparent resin base material sheet contains a vinylidene fluoride resin, and a 2nd transparent resin base material sheet contains acrylic resin. .

[Vacuum forming process]
In the present invention, the decorative sheet as described above is used to simultaneously decorate by injection molding in a form with sheet preforming. At that time, in the vacuum forming step for the sheet preforming, when the transparent resin base sheet uses the decorative sheet having the specific two-layer laminate structure, the sheet heating temperature is preferably The temperature is equal to or higher than the softening temperature of the second transparent resin base sheet and lower than the melting point of the first transparent resin base sheet. As a result, it is possible to ensure the formability during vacuum forming for sheet preforming and to maintain the uneven shape after vacuum forming.

  The vacuum forming process (including vacuum / pressure forming) for preforming a decorative sheet is roughly divided into in-line pre-molding in which a vacuum mold is used as an injection mold and vacuum forming is performed on the injection mold. The form and the vacuum mold may be different from the injection mold, that is, the off-line pre-form where vacuum forming is performed outside the injection molding machine. Note that off-line pre-formation is generally suitable when the decorative molded product size is large or the sheet thickness is thick, as compared with in-line pre-formation.

  The sheet heating temperature at the time of vacuum forming is usually about 100 to 120 ° C. for in-line pre-forming and about 140 to 170 ° C. for off-line pre-forming. Therefore, for example, when the transparent resin base sheet uses a decorative sheet having a specific two-layer laminate structure, a vinylidene fluoride resin is used for the first transparent resin base sheet, and the second transparent resin base sheet is used. A decorative sheet having a configuration using an acrylic resin can be applied to both normal in-line preforming and offline preforming. In addition, the said preforming temperature shows general temperature and you may carry out at the temperature outside the said range according to resin used for the decorating sheet.

[Injection molding process]
In the injection molding process, after the decorative sheet preformed by the vacuum molding process as described above is loaded in the injection mold, the pair of male and female injection molds are clamped, and then in the cavity of the injection mold The resin in a fluid state is injected, filled and solidified, and the decorative sheet is laminated and integrated on the surface of the resin molded product. Then, after the resin is solidified, the mold is opened to take out the target decorative molded product. The decorative molded product is given a three-dimensional design feeling that makes the uneven pattern visually feel by the decorative sheet as described above.

  The injection resin injected into the injection mold is usually heated and melted to be in a fluid state, and its temperature may reach 200 ° C. or higher. Even such a high-temperature injection resin may be used. The uneven shape of the decorative sheet can be maintained. That is, the heat of the injection resin at the time of injection molding does not affect the heat at the time of vacuum molding. For example, when the injection resin is an ABS resin, the decorative sheet is exposed to a temperature condition in which the injection resin temperature is about 200 to 240 ° C and the mold temperature of the injection mold is about 60 ° C. This is because the decorative sheet is applied for a moment, and if the uneven shape can withstand the vacuum forming process, the uneven shape can basically remain on the decorative molded product.

[Others]
Here, the so-called injection molding simultaneous decorating method will be outlined with reference to the conceptual diagram of FIG. In addition, the form demonstrated here is a form of the in-line preforming which performs a vacuum forming process on an injection mold.

  First, as shown in FIG. 6A, as an injection mold, a mold Ma having a runner communicating with the injection nozzle and a gate (gate), a suction hole 41 on the cavity surface, and a decorative sheet A pair of molds of a mold Mb that also serves as a preforming mold for a vacuum forming process is used. These molds are made of metal such as iron or ceramics. In the mold open state, the decorative sheet S is supplied between both molds Ma and Mb, and the decorative sheet S is fixed to the mold Mb by pressing it with a sheet clamp 42 having a frame shape in plan view. At this time, it is a matter of course that the back side of the decorative sheet (relative to the transparent resin base sheet) on the side of the glittering layer is the injection resin side on the right side of the drawing. Next, as shown in FIG. 6B, the heater 43 that has been retracted at the retracted position outside the mold (in the drawing, above the mold) is appropriately moved and inserted between both molds, and the decorative sheet is heated by the heater 43. Soften. The heating is, for example, non-contact radiation heating, but may be conduction heating by contact. Then, vacuuming is performed by suction from the suction hole, and the decorative sheet is preformed along the cavity surface of the mold Mb. Next, the heater is retracted from between both molds, and both molds are clamped as shown in FIG. 6C, and a cavity formed by both molds is filled with a resin in a fluid state such as a heat-melted state. And after resin solidifies by cooling etc., a mold is opened and a molding is taken out. And if the unnecessary part of a decorating sheet is trimmed suitably, as shown in FIG. 4, the decorating molded product Pd by which the decorating sheet S was laminated | stacked on the resin molding 5 and decorating is obtained. In the present invention, the decorative sheet enables the expression of a three-dimensional design that makes the uneven pattern visually feel by the decorative sheet.

  A decorative sheet S5 having the structure as shown in FIG. 3 was produced as follows. First, a vinylidene fluoride resin (melting point Tm 160 ° C.) which is a fluororesin of a crystalline resin and an acrylic resin (VICAT softening temperature Ts 118 ° C.) which is an amorphous resin are coextruded to obtain a thickness. A transparent resin substrate sheet 1 in which a first transparent resin substrate sheet 11 having a thickness of 8 μm and a second transparent resin substrate sheet 12 having a thickness of 72 μm were laminated was prepared.

  Next, on the surface of the transparent resin base sheet 1 on the second transparent resin base sheet 12 side, an acrylic resin is used as a binder resin, and an aluminum scaly foil piece (average particle size 14 μm) is added as a bright pigment. The glitter layer 2 is formed by gravure printing using the silver ink, and further, an ink composed of a mixed resin of 1: 1 mass ratio of acrylic resin and vinyl chloride-vinyl acetate copolymer is printed twice by gravure printing. Then, an adhesive layer (not shown) was formed to obtain a printed sheet.

  Next, by the embossing as shown in FIG. 5 as described above, the surface of the first transparent resin substrate sheet 11 made of vinylidene fluoride resin is viewed from the surface with a rough surface with minute irregularities having a center line average roughness Ra of 5 μm. And a flat low-gloss region L and a high-gloss region H having a concave surface when viewed from the surface on a smooth surface having a center line average roughness Ra of 0.1 μm. The height difference between the concave portion and the convex portion was 10 μm. The low gloss region L and the high gloss region H are elongated striped regions each having a width of 100 to 200 μm, and the two regions are alternately arranged to form a hairline pattern as a whole. On the other hand, for the second transparent resin base sheet 12 made of acrylic resin and the glitter layer 2, the concave region as viewed from the back side is formed in the portion facing the low gloss region L, and the portion facing the high gloss region H is formed. A convex region was formed when viewed from the back side. The height difference between the two regions was 80 μm. In addition, the surface temperature of the 1st transparent resin base material sheet 11 at the time of embossing was 180 degreeC by the heating of the infrared radiation heater. Moreover, the 2nd transparent resin base material sheet 12 was heated with the heat of conduction from the heating metal drum with the surface temperature of 150 degreeC.

  Next, in order to perform the injection molding simultaneous decorating of the decorative sheet S obtained above in the form of in-line preforming in which the injection mold is also used as the vacuum molding mold, the glittering layer side is provided on the injection molding simultaneous decorating apparatus. Non-contact heating of a decorative sheet with a heater on the condition of a sheet heating temperature of 120 ° C. on a female mold of an injection mold that is mounted so as to face the gate side of the male mold of the injection mold Then, the decorative sheet was vacuum molded into the shape of the injection mold by vacuum suction from the injection mold side. About the decorative sheet after vacuum forming, when the state of the concavo-convex pattern was confirmed, the concavo-convex shape remained.

  Thereafter, the injection mold was clamped and the ABS resin was injection molded. The mold temperature of the injection mold was 60 ° C., and the injection resin temperature was 240 ° C. After opening the mold, the decorative molded product is taken out, and when the remaining state of the concavo-convex pattern in the molded product is confirmed, the concavo-convex pattern is left on the decorative molded product, including minute irregularities on the surface. A three-dimensional design feeling that makes you feel visually is expressed, and it has become a highly designed molded product.

[Comparative Example 1]
In Example 1, instead of the transparent resin base sheet having a two-layer laminate structure in which the first transparent resin base sheet and the second transparent resin base sheet are stacked, an acrylic resin (VICAT softening temperature 118 ° C. A transparent resin base sheet with a thickness of 80 μm was used. Other than this, a decorative sheet was produced in the same manner as in Example 1. And as a result of trying production of a decoration molded product by the injection molding simultaneous decorating method similar to Example 1, as a result, the uneven | corrugated shape including a micro unevenness | corrugation of a surface lose | disappears in the decorative sheet after vacuum forming. However, the three-dimensional design feeling that makes the concavo-convex pattern feel visually disappeared. For this reason, the next injection molding process was stopped.

DESCRIPTION OF SYMBOLS 1 Transparent resin base material sheet 11 1st transparent resin base material sheet 12 2nd transparent resin base material sheet 2 Glossy layer 3 Decoration layer 4 Backing sheet 5 Resin molding 41 Suction hole 42 Sheet clamp 43 Heater A Low embossing pressure area B High embossed pressure area C Rubber impression cylinder E Metal embossed plate ep (embossed plate) convex portion er (embossed plate) concave portion Fr Rough surface H High gloss region Hf High gloss region (flat)
Hp High gloss area (convex shape)
Hr High-gloss area (concave shape)
L Low gloss area Ma Injection mold (male mold)
Mb injection mold (female)
Pd decorative molded product p protruding part S, S1 to S5 decorative sheet

Claims (9)

A transparent resin base sheet is laminated with a glittering layer on the back surface, and the surface of the transparent resin base sheet is a relatively high gloss area with a relatively high gloss compared with the surrounding area and a relatively low gloss with respect to the surrounding area. The transparent resin substrate sheet is divided into a low gloss region, and the transparent resin base sheet is formed to be relatively thick in the high gloss region and relatively thin in the low gloss region. The resin substrate sheet is composed of a two-layer laminate of a first transparent resin substrate sheet located on the front surface side and a second transparent resin substrate sheet located on the back surface side, and the first transparent resin substrate sheet is a crystal. The second transparent resin base sheet is made of an amorphous resin, the melting point of the first transparent resin base sheet is higher than the softening temperature of the second transparent resin base sheet, and the high gloss region In addition, an uneven pattern corresponding to low gloss areas is visually expressed. , Decorative sheet. The decorative sheet according to claim 1, wherein the decorative sheet has a decorative layer between the transparent resin base sheet and the glitter layer so as not to completely hide the glitter of the glitter layer . The decorative sheet according to claim 1 or 2, wherein a backing sheet made of a thermoplastic resin is laminated on the back surface of the glitter layer . In the back surface of a transparent resin base material sheet, the part corresponding to the high-gloss area | region of this base material sheet surface is convex toward the back surface direction, In any one of Claims 1-3. The decorative sheet as described . A decorative molded product, wherein the decorative sheet according to any one of claims 1 to 4 is laminated on the surface of the resin molded product so that the transparent resin base sheet side is positioned on the surface side. . The decorative molded product according to claim 5, wherein in the high gloss region of the transparent resin base sheet, the back surface is convex toward the back surface and the front surface is a flat surface . The decorative molding according to claim 5, wherein in the high gloss region of the transparent resin base sheet, the back surface is convex toward the back surface and the front surface is concave toward the surface direction. Goods . Simultaneously with the injection molding using the decorative sheet, the vacuum molding process and the injection molding process are performed, and at the same time as the molding of the resin molded product, the decorative sheet is integrated on the surface thereof to make the resin molded product a decorative molded product. In the decoration method, at least,
(A) A laminated body including a transparent resin substrate sheet and a glitter layer is heated, and embossing is performed to obtain a high gloss region and a low gloss region on the surface of the transparent resin substrate sheet, and the high gloss region and the low gloss region. The sheet preparation process which manufactures the decorating sheet of any one of Claims 1-4 by forming the thickness of the thickness of the transparent resin base material sheet corresponding to this,
(B) Vacuum forming step of heat-softening the decorative sheet and vacuum forming into a shape corresponding to a desired molded product shape,
(C) A resin in a fluid state is placed in the injection mold in a state where the vacuum-formed decorative sheet is loaded in the clamped injection mold so that the surface side faces the injection mold surface. Injection molding which solidifies the resin by injection-filling and laminates and integrates a decorative sheet on the surface of the resin molded product to obtain the decorative molded product according to any one of claims 5 to 7. Process,
The injection molding simultaneous decoration method which performs each of these processes in this order . In the sheet creation step of step (A), embossing is performed at a temperature equal to or higher than the melting point of the first transparent resin substrate sheet,
The injection molding according to claim 8, wherein in the vacuum forming step of the step (B), vacuum forming is performed at a temperature that is equal to or higher than a softening temperature of the second transparent resin base sheet and lower than a melting point of the first transparent resin base sheet. Simultaneous decoration method .

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