JP5777714B2 - フィルムで被覆された成形品の製造法 - Google Patents
フィルムで被覆された成形品の製造法 Download PDFInfo
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- JP5777714B2 JP5777714B2 JP2013523741A JP2013523741A JP5777714B2 JP 5777714 B2 JP5777714 B2 JP 5777714B2 JP 2013523741 A JP2013523741 A JP 2013523741A JP 2013523741 A JP2013523741 A JP 2013523741A JP 5777714 B2 JP5777714 B2 JP 5777714B2
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
- B32B37/0023—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality around holes, apertures or channels present in at least one layer
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/022—Mechanical pre-treatments, e.g. reshaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/006—Using vacuum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/42—Heating or cooling
- B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0097—Glues or adhesives, e.g. hot melts or thermofusible adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/722—Decorative or ornamental articles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Manufacturing & Machinery (AREA)
- Laminated Bodies (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Description
基体の製造
(1)樹脂製基体(ア)の製造
テクノポリマー株式会社製のABS/PCアロイ樹脂(エクセロイ(商品名)CK50)を温度100℃で4時間かけて予備乾燥した後、三菱重工プラスチックテクノロジー株式会社製の100トン射出成形機S−2000i 100Aを使用して、シリンダー温度260℃、金型温度70℃、射出速度250mm/sec、保持圧50MPaにて射出成形を行い、図3に示す形状の熱可塑性樹脂製の基体を得た。図3は、実施例1の成形品を写真撮影したものである。この基体の表面に、新東工業株式会社製のブラスト機(マイブラストMY−30D(商品名))を用いて、空気圧0.3MPaおよび角度30〜60°の条件で、ガラスビーズJ−220(中心粒度75〜45μm)を噴き付けた。噴き付け時間は、基体の表面が所定の表面粗さになるように1〜20秒程度の範囲で適宜調節した。噴き付けた後、基体を十分に水洗し、乾燥させて、所定の表面粗さ(A)を有する樹脂製基体(ア)を得た。
コマツ産機株式会社製のプレス機(OBS80S(商品名))を使用して、日本軽金属株式会社製のアルミ板(A5052(商品名)、厚み2mm)の絞り加工を行い、基体(ア)と同様の形状を有する金属製の基体を得た。この基体の表面に、上記樹脂製基体と同様の方法でガラスビーズを噴き付けて所定の表面粗さ(A)を有する金属製基体(イ)を得た。
上記で得られた樹脂製および金属製の基体の表面粗さ(A)(最大高さ平均(Rtm))を、株式会社東京精密製の粗度計(ハンディサーフE−40A)を用いて測定した。後述するフィルムの表面粗さ(B)(最大高さ平均(Rtm))についても同様に測定した。
(1)アクリル系粘着剤層を有するフィルム(α0)の製造
綜研化学社製のアクリル系粘着剤(SKダイン1309(商品名)、組成:アクリル酸及びアクリル酸エステル)および綜研化学社製の硬化剤(L−45、組成:トリレンジイソシアネート)を、溶剤としてのトルエンおよび酢酸エチルと共に1000:6:100:100の重量比で混合し、室温にて2分間よく攪拌した。この混合物を、東レフィルム加工社製の剥離フィルム(セラピールWZ(商品名)、厚み38μm)に塗布し、100℃にて2分間乾燥させて厚み30μmの粘着剤層を得た。この粘着剤層の上に、基材層としての、リケンテクノス株式会社のシクロヘキサンジメタノール共重合ポリエチレンテレフタレートフィルム(PETG樹脂フィルム、SET329 FZ26401(商品名)、厚み100μm)を貼り合わせて、アクリル系粘着剤層を有するフィルム(α0)を得た。なお、粘着剤のガラス転移点は−25℃、粘度は10Pa・s(25℃)であった。また、粘着剤層の剥離フィルムと接している面の表面粗さは、2μmであった。
上記(1)のフィルムの製造において、剥離フィルムとして、その表面が以下のように処理されたユニチカ株式会社製エンブレットS100を使用した以外は、上記フィルムの製造と同様にして、アクリル系粘着剤層を有し、かつ粘着剤層の剥離フィルムと接している面が種々の表面粗さを有するフィルム(α)を得た。剥離フィルムは、上記エンブレットS100の表面に、新東工業株式会社製のブラスト機(マイブラストMY−30D)を用いて空気圧0.3MPaおよび角度30〜60°の条件でガラスビーズJ−220(中心粒度75〜45μm)を噴き付け、水洗後乾燥し、上記表面をシリコーン処理したものである。噴き付け時間は、剥離フィルムの粘着剤層と接する面が所定の表面粗さ(B)になるように1〜20秒程度の範囲で適宜調節した。
上記(2)のフィルムの製造において、アクリル系粘着剤層に代えて、下記のポリエステル系接着剤層を使用した以外は、上記(2)のフィルムの製造と同様にして、ポリエステル系接着剤層を有するフィルム(β)を得た。上記接着剤層は、以下のようにして得た。酸成分としてのテレフタル酸、イソフタル酸およびアジピン酸を30:30:40のモル比で有し、グリコール成分としての1,4−ブタンジオールおよび1,6−ヘキサンジオールを25:75のモル比で有するように、これらの化合物を適当量配合し、触媒(テトラブチルチタネート)の存在下で加熱して、熱可塑性飽和共重合ポリエステル樹脂を合成した。得られた熱可塑性飽和共重合ポリエステル樹脂を溶剤(メチルエチルケトン)に溶解し、固形分30質量%の溶液とした。この溶液にポリイソシアネート(日本ポリウレタン工業株式会社製、「コロネートHX」(ヘキサメチレンジイソシアネート)、固形分100%)を2当量加え、室温にて2分間よく攪拌した。この混合物を、上記(2)と同様の剥離フィルムに塗布して厚み30μmの接着剤層を得た。なお、ガラスビーズの噴き付け時間は、接着剤層の、剥離フィルムと接する面の表面粗さ(B)が13μmになるように調節した。また、接着剤のガラス転移点は23℃、粘度は25Pa・s(25℃)であった。
(1)外観性
成形品のフィルム表面の外観を下記の評価基準にしたがって目視評価した。
○:膨れや凹凸が認められない。
△:極僅かな膨れや凹凸が認められる。
×:指で触れて引っかかる程度の大きな膨れや凹凸が認められる。
成形品のフィルム表面に100×25mmの切り込みを入れ、一方の端部を引き剥がし、この端部と成形品の端部をA&D製テンシロンRTG−1310引張試験機のチャックに固定し、引張速度300mm/minで剥離強度を測定した。
○:剥離強度が30N/25mm以上
△:剥離強度が20N/25mm以上30N/25mm未満
×:剥離強度が20N/25mm未満
成形品を100℃のギヤーオーブンに168時間放置した後に取り出し、更に室温で1時間以上放置した後、成形品の外観を下記の評価基準にしたがって目視評価した。
○:成形品に膨れや凹凸などが認められない。
△:成形品に極軽微な膨れや凹凸などが認められる。
×:成形品に指で触れて引っかかる程度の大きな膨れや凹凸が認められる。
2 ヒーター
3 基体
4 フィルムと基体との間の空間
5 成形品
6 基体
7 上室
8 下室
9 ヒーター
10 成形品
Claims (6)
- 基体を有し、その表面の一部又は全部がフィルムで被覆された成形品を製造する方法であって、該フィルムは接着層を有し、該接着層が該基体と接しており、該基体の該接着層と接している面の表面粗さ(A)が3〜20μmであり、該方法が、前記基体の表面の一部又は全部を前記フィルムで被覆する工程を含み、該被覆の前におけるフィルムの接着層の該基体と接する面の表面粗さ(B)が3〜20μmであり、該被覆が真空成形法または真空圧空成形法によって行われる、前記方法。
- 前記被覆が真空圧空成形法によって行われ、該真空圧空成形法が、下記の順次の工程:
(a)前記フィルムを成形室内の中央部に置くこと、
(b)成形室内の該フィルムより下の部分である下室に前記基体を該フィルムと接するように設置すること、
(c)下室と成形室内の該フィルムより上の部分である上室を1KPa以下に減圧すること、
(d)該フィルムを加熱して軟化させること、および
(e)上室を150〜500KPaに加圧してフィルムと基体を密着させること
を含む、請求項1に記載の方法。 - 前記被覆が真空成形法によって行われ、該真空成形法が、下記の順次の工程:
(a)前記フィルムを加熱して軟化させること、
(b)軟化したフィルムを前記基体に接するように置くこと、および
(c)該フィルムと該基体との間の空間を1KPa以下に減圧してフィルムを基体に密着させること
を含む、請求項1に記載の方法。 - 前記接着層が、ガラス転移点が−10〜50℃である接着剤からなる、請求項1〜3のいずれか1項記載の方法。
- 前記接着層が、ガラス転移点が−70〜−10℃である粘着剤からなる、請求項1〜3のいずれか1項記載の方法。
- 前記フィルムが熱可塑性樹脂層および接着層からなり、該熱可塑性樹脂層が、ポリ塩化ビニル樹脂、非結晶性ポリエステル樹脂およびアクリル樹脂からなる群から選択される1以上を含む、請求項1〜5のいずれか1項記載の方法。
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CN103754404A (zh) * | 2014-01-30 | 2014-04-30 | 王金龙 | 一种表面包覆方法及装置 |
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DE102015012242B4 (de) * | 2015-09-18 | 2019-06-19 | Leonhard Kurz Stiftung & Co. Kg | Verfahren und Vorrichtung zur Herstellung eines mit einem Schichtstoff kaschierten 3D-Substrates |
TWI606911B (zh) * | 2015-11-27 | 2017-12-01 | 遠東科技大學 | 射出成形機及其使用的表面裝飾模具 |
TWI625217B (zh) * | 2015-11-27 | 2018-06-01 | 遠東科技大學 | 射出成形方法及由該方法製造的成形品 |
KR101839481B1 (ko) * | 2016-06-17 | 2018-03-16 | 주식회사 캐리마 | 3d 프린팅 및 진공흡착 공정을 이용한 인공안구 제조방법 |
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JP2019042927A (ja) * | 2017-08-29 | 2019-03-22 | 共和レザー株式会社 | 加飾成形体及び加飾成形体の製造方法 |
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JP6691624B2 (ja) * | 2019-04-22 | 2020-04-28 | 株式会社浅野研究所 | 熱成形装置及び熱成形方法 |
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KR20140034233A (ko) | 2014-03-19 |
WO2013008318A1 (ja) | 2013-01-17 |
US20140147630A1 (en) | 2014-05-29 |
KR101802556B1 (ko) | 2017-11-28 |
EP2732952A4 (en) | 2015-04-15 |
US10369770B2 (en) | 2019-08-06 |
ES2625793T3 (es) | 2017-07-20 |
JPWO2013008318A1 (ja) | 2015-02-23 |
EP2732952B1 (en) | 2017-03-01 |
EP2732952A1 (en) | 2014-05-21 |
CN103826827B (zh) | 2016-04-27 |
US20150375443A1 (en) | 2015-12-31 |
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