JP6107223B2 - Decorative molding decorative sheet having internal irregularities and method for producing the same - Google Patents

Description

  The present invention relates to a decorative sheet used for decorating a car interior panel, a mobile phone, a personal computer casing, and the like, and particularly relates to a decorative sheet that is excellent in design and can be given a design having a sense of unevenness inside.

  In recent years, inserts and in-mold molded products have a tendency to place importance on design. Especially, the case of mobile phones, personal computer housings, etc. is said to have a great influence on the sales by design.

  The decorative decorative decorative sheet is a transfer sheet that simply transfers the pattern layer to the molded product, or a sheet that is provided with a pattern layer on a transparent or translucent thermoplastic resin sheet. A decorative sheet used by being bonded to a base material is used.

  However, in the present situation, in the sheet provided with a pattern layer on the transfer sheet or the transparent or translucent thermoplastic resin sheet, only a flat design expression that can be expressed by the pattern layer is present.

  Therefore, as a method for three-dimensional expression on the decorative molding sheet, a thermoplastic resin layer such as an olefin resin, an acrylic resin or a polyester resin is provided on the outermost surface of the sheet, and irregularities are formed by a hot roll embossing method. There has been proposed a method for forming the. However, since the unevenness | corrugation is formed in the outermost surface of a sheet | seat, there exists a problem that the surface wears by friction and a design feeling changes with time (patent document 1).

  In addition, a method has been proposed in which a curable resin is applied to a plate surface of a roll intaglio, and then the curable resin is cured to form a concavo-convex pattern while the roll intaglio is brought into close contact with the decorative molding sheet. However, since the curable resin is used for the resin layer that forms the unevenness, the wear resistance has been improved, but in the process of vacuum forming or insert molding, the unevenness does not extend uniformly when the sheet is overheated and stretched. Is non-uniform (Patent Document 2).

  In addition, a method of forming irregularities inside the sheet is shown. Because the unevenness is inside the seat, it not only expresses a design with a unique depth, but also has excellent wear resistance and shaping performance, but it is used for parts that are exposed to high temperatures for a long time, such as automotive interior panels. When used, there is a problem that the unevenness formed inside disappears gradually and the design feeling is impaired (Patent Document 3).

Japanese Patent No. 4918933 JP-A-7-32476 JP 2012-30418 A

The present invention has been made in order to solve the above-mentioned problems, and has a concavo-convex shape in the interior of the pattern layer and the sheet, has a high design, and maintains design uniformity even by heat and stretching during molding. An object of the present invention is to provide a decorative molding decorative sheet in which molded parts are provided for in-vehicle use or the like, and even if they are exposed to high temperatures for a long period of time, the internal irregularities do not disappear and the design properties are not impaired. .

As means for solving the above-mentioned problems, the invention according to claim 1 is characterized in that a pattern layer is provided on one surface of the first transparent or translucent thermoplastic resin sheet, and the pattern pattern layer is provided on the surface. A decorative transparent decorative sheet having a concavo-convex shape and a melt-extruded thermoplastic resin layer provided on the surface provided with the concavo-convex shape so as to fill a concave portion, the first transparent or translucent thermoplastic resin deflection temperature under load in the load 1.80MPa of the sheet Ri range der of 120~160 ℃,
The deflection temperature under load of 1.80 MPa of the melt-extruded thermoplastic resin layer is 120 ° C. or higher, and the melt-extruded thermoplastic resin layer is formed on the first transparent or translucent thermoplastic resin sheet. deformation due to thermal behavior is decorative sheet for decorative molding having an internal irregularities characterized by the same or substantially the same der Rukoto.

The invention according to claim 2, wherein in the first transparent or decorative molding decorative sheet having internal irregularities of claim 1, wherein the semi-transparent thermoplastic resin sheet is a polycarbonate is there.

Further, the invention according to claim 3 is the first transparent or translucent thermoplastic resin sheet is a coextruded film of polycarbonate and acrylic resin, and is laminated so that the outermost surface is an acrylic resin. The decorative decorative sheet for decorative molding having internal irregularities according to claim 1 .

The invention according to claim 4 is characterized in that the melt-extruded thermoplastic resin layer is polycarbonate, and the decorative molding decorative sheet having internal irregularities according to any one of claims 1 to 3. It is.

Further, the invention according to claim 5 is the second transparent or the transparent or translucent thermoplastic resin sheet on the surface opposite to the surface provided with the pattern layer, through the adhesive layer. The decorative molding decorative sheet according to any one of claims 1, 2, and 4, wherein an acrylic resin sheet is bonded as a translucent thermoplastic resin sheet.
The invention according to claim 6 is a method of manufacturing a decorative sheet for decorative molding,
A step of providing a pattern layer on one surface of the first transparent or translucent thermoplastic resin sheet, a step of providing an uneven shape on the surface provided with the pattern layer, and a recess on the surface provided with the uneven shape. Providing at least a thermoplastic resin layer by a melt extrusion method so as to be filled,
The deflection temperature under load of 1.80 MPa of the first transparent or translucent thermoplastic resin sheet is in the range of 120 to 160 ° C.,
The deflection temperature under load of 1.80 MPa of the melt-extruded thermoplastic resin layer is 120 ° C. or higher, and the melt-extruded thermoplastic resin layer is formed on the first transparent or translucent thermoplastic resin sheet. It is a method for producing a decorative molding decorative sheet, wherein the deformation due to thermal behavior is the same or substantially the same.

  As described above, in the present invention, a pattern layer is provided on one surface of the first transparent or translucent thermoplastic resin sheet, an uneven shape is provided on the surface provided with the pattern layer, and the uneven surface is provided on the surface. In the decorative sheet provided with the melt-extruded thermoplastic resin layer so as to fill the concave portion, the deflection temperature under load of 1.80 MPa of the first transparent or translucent thermoplastic sheet is in the range of 120 to 160 ° C. Even in the process of producing a molded product using the decorative sheet of the present invention, it is possible to maintain the uniformity of the unevenness formed inside, and the internal uneven shape even if the molded product is exposed to high temperature for a long time. There is an effect that does not disappear.

It is a schematic cross section showing an example of an embodiment of a decorative molding decorative sheet according to the present invention. It is a schematic cross section which shows another embodiment of the decorative sheet for decorative molding in invention. It is a schematic cross section which shows another embodiment of the decorative sheet for decorative molding in invention.

Hereinafter, embodiments of the present invention will be described in detail. FIG. 1 shows a cross-sectional structure relating to one embodiment of a decorative molding decorative sheet according to the present invention. The decorative molding decorative sheet 10 composed of the first transparent or translucent thermoplastic resin sheet 1, the pattern layer 2, the uneven shape 3, and the melt-extruded thermoplastic resin layer 4 is provided in this order.

  Further, an adhesive layer or a pressure-sensitive adhesive layer 5 may be provided as appropriate for bonding with a resin molded product when vacuum forming is performed. Further, for the purpose of protecting the surface of the decorative molding decorative sheet 10, the second transparent or translucent thermoplastic is provided on the first transparent or translucent thermoplastic resin sheet 1 via the adhesive layer 6. A resin sheet 7 may be provided.

  As the first transparent or translucent thermoplastic resin sheet 1 in the present invention, by using a sheet manufactured from a resin having a load deflection temperature in a range of 120 to 160 ° C. under a load of 1.80 MPa, Even if it is exposed to, the shape loss of the uneven shape 3 does not occur.

  Moreover, in order to form the pattern pattern layer 2, it is necessary to have printability, and also to have stretchability for performing decorative molding. Specifically, polycarbonate resin, polytetrafluoroethylene resin, and the like can be used, and can be mixed with other resins as long as transparency is not impaired. However, polycarbonate is suitable particularly when transparency is required. It is. The thickness needs to be thick enough to provide the uneven shape 3 and maintain the surface physical properties, but is preferably 30 to 300 μm.

  If the deflection temperature under load is too low, the molded product decorated with the decorative molding decorative sheet 10 is exposed to a high temperature for a long period of time, so that the uneven shape 3 provided on the pattern layer 2 disappears, and the deflection temperature under load is lost. If it is too high, it becomes difficult to provide the uneven shape 3. The deflection temperature under load shown here is a value measured by the method shown in JIS K7191.

  The pattern layer 2 in the present invention can be provided as a layer made of ink on the first transparent or translucent thermoplastic resin sheet 1 by printing. The ink can be appropriately selected in consideration of adhesion depending on the type of the first transparent or translucent thermoplastic resin sheet 1.

  The printing method is not particularly limited. However, when the elongation at the time of molding is large, it is necessary to increase the thickness of the layer. Therefore, screen printing or the like is desirable. Further, printing with ink added with a luster pigment is preferable because the expression by the uneven shape 3 is more conspicuous and the range of design expression is expanded. In addition, an adhesive 6 may be appropriately applied on the pattern layer 2 in consideration of adhesion with a melt-extruded thermoplastic resin layer 4 described later.

  As the concavo-convex shape 3 in the present invention, a metal or resin embossed plate or emboss roll having concavo-convex in a state where the first transparent or translucent thermoplastic resin sheet 1 is heated and softened is used as the pattern. A desired shape can be imparted by pressure bonding from the layer 2 side and cooling.

  Further, the processing temperature condition is that the first transparent or translucent heat is applied so that the molded product decorated with the decorative molding decorative sheet 10 is not exposed to a high temperature for a long period of time, so that the concavo-convex shape is not lost. It is necessary to carry out at a temperature higher than the deflection temperature under load of the plastic resin sheet 1.

  As the melt-extruded thermoplastic resin layer 4 in the present invention, a molded product having a viscosity that can be filled in the concave portion of the concave and convex shape 3 without a gap in a molten state and decorated with a decorative molding decorative sheet 10 is long. A resin that does not lose the shape of the uneven shape 3 even when exposed to a high temperature for a period is desirable.

Specifically, selected from resins having a deflection temperature under load of 120 ° C. or higher, such as polyethersulfone resin, polycarbonate resin, polytetrafluoroethylene resin, polyetherimide resin, polyamideimide resin, and exposed to high temperature for a long time. Also, the shape loss of the uneven shape 3 does not occur.
In consideration of the close contact with the pattern / pattern layer 2, an adhesive resin may be co-extruded on the pattern / pattern layer 2 side when the melt-extruded thermoplastic resin layer 4 is extruded. The resin can also be colored as necessary.

  In the process of bonding the decorative molding decorative sheet 10 to the molded part, the stress of heating, stretching, and cooling is applied to the entire decorative molding decorative sheet 10. In this process, when the thermal behavior of the first transparent or translucent thermoplastic resin sheet 1 and the melt-extruded thermoplastic resin layer 4 is deviated, the uneven shape 3 is deformed.

  Since the deformation of the concavo-convex shape 3 results in a deterioration of the design, the material of the melt-extruded thermoplastic resin layer 4 needs to have the same thermal behavior as that of the first transparent or translucent thermoplastic resin sheet 1 as much as possible. . The same resin component is more preferable.

  Furthermore, another embodiment of the present invention is shown in FIG. In addition to the embodiment shown in FIG. 1, the second transparent or translucent thermoplastic resin sheet 7 determines the surface physical properties of the sheet and is appropriately selected in consideration of the required surface physical properties and molding shape. Although possible, an acrylic resin sheet, an easily-molded polyester resin sheet, and the like can be given.

  Moreover, in order to adhere | attach with the 1st transparent or translucent thermoplastic resin sheet 1, the adhesive bond layer 6 can be interposed. The adhesive layer 6 is not particularly limited, but the layer thickness may be slightly uneven on the surface opposite to the surface provided with the uneven shape of the first transparent or translucent thermoplastic resin sheet 1. It is sufficient that the thickness of the surface is smooth, specifically 0.5 to 1.5 μm. The adhesive layer 6 is preferably transparent or translucent.

  As the adhesive layer or the pressure-sensitive adhesive layer 5 in the present invention, it is required to adhere to a molding resin when decorating the decorative molding decorative sheet 10 on a molded product, and a material suitable for various decorative molding methods is used. Can be selected. For example, in the vacuum forming method or the vacuum / pneumatic forming method, the decorative sheet is disposed on the side of the resin part in which the adhesive layer or the pressure-sensitive adhesive layer 5 is pre-formed, and the decorative sheet is heated and softened so as to follow the shape of the resin part. Paste to.

  Therefore, the adhesive layer or the pressure-sensitive adhesive layer 5 needs to be a material having adhesiveness or tackiness at the temperature of the process of heating the decorative sheet. The temperature in the step of heating the decorative molding decorative sheet 10 needs to be a temperature at which the decorative molding decorative sheet 10 can be stretched to the extent that it can follow the shape of the resin component, and is 150 ° C. or higher.

  Further, as the decorative molding method, an insert molding method in which decoration and resin molding are simultaneously performed can be selected. In the insert molding method, at the time of molding, the decorative resin is brought into contact with the decorative molding decorative sheet 10 in a state where the molding resin is melted. The temperature at that time varies depending on the temperature of the molding resin, but is generally 200 ° C. or higher.

  Therefore, the adhesive layer or the pressure-sensitive adhesive layer 5 may be made of a material that can be bonded to the molding resin at the above temperature. Depending on the type of the molding resin and the insert molding temperature, the decorative sheet may not be provided with the adhesive layer or the pressure-sensitive adhesive layer 5, and even the melt-extruded thermoplastic resin layer 4 can be in close contact with the molding resin.

A polycarbonate resin film (thickness 120 μm, deflection temperature under load (1.8 MPa) 135 ° C.) was used as the first transparent or translucent thermoplastic resin sheet 1, and a luster pigment was added to a urethane resin gravure ink on this surface. Ink was overprinted by gravure printing to provide a woodgrain pattern layer 2 by printing A single striped pattern consisting of a plurality of parallel straight stripes with fine spacing is provided on the pattern layer 2. The embossing is set to a sheet temperature of 190 ° C. using an embossed plate with a fine stone pattern formed by combining the stripe directions of adjacent unit stripe patterns so that they are different from each other. Embossing was carried out with a machine, and after cooling to 30 ° C. as it was, the embossed plate was peeled off to give the irregular shape 3.

  The surface provided with the uneven shape 3 is melt-extruded so as to fill the concave portion of the uneven shape 3 with a polycarbonate resin (thickness 80 μm, deflection temperature under load (1.8 MPa) 130 ° C.) as a molten thermoplastic resin layer 4, A molten thermoplastic resin layer 4 was provided.

A second transparent or semi-transparent adhesive layer 6 is formed on the surface opposite to the surface of the first transparent or translucent thermoplastic resin sheet 1 on which the pattern layer 2 is provided via a polyester adhesive. An acrylic resin sheet (thickness: 100 μm) was bonded as the transparent thermoplastic resin sheet 7.

  In addition, a decorative adhesive decorative sheet 10 having internal irregularities according to the present invention was prepared by providing a urethane adhesive on the surface of the molten thermoplastic resin layer 2 to provide an adhesive layer or an adhesive layer 5.

  The melt thermoplastic resin layer 4 in Example 1 was melt extruded by changing the polycarbonate resin to an acrylic resin (thickness 80 μm, deflection temperature under load (1.8 MPa) 95 ° C.) and filling the concave portion of the concave and convex shape 3. The molten thermoplastic resin layer 4 is provided. The other conditions were the same as in Example 1, and a decorative molding decorative sheet 10 was produced.

  As the first transparent or translucent thermoplastic resin sheet 1, a coextruded film of polycarbonate and acrylic resin (thickness: 188 μm, deflection temperature under load (1.8 MPa) 125 ° C.) is used, and the outermost surface is acrylic resin. In addition, an ink obtained by adding a luster pigment to urethane resin gravure ink was overprinted by gravure printing to provide a woodgrain pattern layer 2 by printing.

  On the picture pattern layer 2, a striped pattern composed of a plurality of parallel straight strips with a fine interval is formed as a single unit, and the strips of adjacent unit striped patterns are combined so that the strip directions are different from each other. Using the embossed plate with a fine stone pattern that was formed, embossing was performed with an embossing machine set at a temperature of 190 ° C, and the embossed plate was peeled off after cooling to 30 ° C. Shape 3 was applied.

  The surface provided with the uneven shape 3 is melt-extruded so as to fill the concave portion of the uneven shape 3 with a polycarbonate resin (thickness 80 μm, deflection temperature under load (1.8 MPa) 130 ° C.) as a molten thermoplastic resin layer 4, A molten thermoplastic resin layer 4 was provided.

  In addition, a decorative adhesive decorative sheet 10 having internal irregularities according to the present invention was prepared by providing a urethane adhesive on the surface of the molten thermoplastic resin layer 2 to provide an adhesive layer or an adhesive layer 5.

<Comparative example>
Acrylic film (thickness 125 μm) as the first transparent or translucent thermoplastic resin sheet 1
The deflection temperature under load (1.8 MPa) was 95 ° C.) and the embossing temperature was 125 ° C., and an acrylic resin (thickness 80 μm, deflection temperature under load (1.8 MPa) 95 ° C.) was used as the melt-extruded thermoplastic resin layer 4. Except this, the decorative molding decorative sheet 10 was produced using the materials and processing conditions described in Example 1.

  Using Examples 1 and 2 and Comparative Example 1, a decorative molded part was prepared by bonding to a resin molded part by a vacuum molding method. In addition, the temperature which heated the sheet | seat in the vacuum forming method is 150 degreeC. Thereafter, the decorative molded part was heated to 120 ° C. and left for 500 hours to conduct a heat resistance test. The results are shown in Table 1.

実施例１〜３では、真空成形工法後および耐熱試験後でもシート内部に施された凹凸形状が保持できているため、意匠の変化は認められなかった。しかし、比較例１では耐熱試験において加飾成形部品が長期間高温に晒されたため、シート内部に施された凹凸が消失してしまい、意匠の著しい低下が認められた。

In Examples 1-3, since the uneven | corrugated shape given inside the sheet | seat was hold | maintained after the vacuum forming method and the heat test, the change of the design was not recognized. However, in Comparative Example 1, the decorative molded part was exposed to a high temperature for a long time in the heat resistance test, so that the unevenness applied to the inside of the sheet disappeared, and the design was significantly lowered.

  The decorative molding decorative sheet 10 of the present invention can retain the irregular shape applied inside even after the heat resistance test of the decorative molded part as well as the decorative molding process, so that the design does not disappear, It has been found that it is possible to provide an excellent design for decorating molded products such as automobile interior panels, mobile phones, and personal computer casings.

  In addition, the concavo-convex shape is maintained by providing the molten thermoplastic resin layer 4 by melting and extruding a polycarbonate resin (thickness 80 μm, deflection temperature under load (1.8 MPa) 130 ° C.) so as to fill the concave portion of the concavo-convex shape 3. Is further improved.

  Moreover, the surface property of a back surface improves by sticking an acrylic resin sheet as a 2nd transparent or translucent thermoplastic resin sheet to a back surface.

  From Example 2, as the first transparent or translucent thermoplastic resin sheet 1, an acrylic resin layer is provided on a polycarbonate, and the outermost surface is an acrylic resin, whereby the surface property is improved.

DESCRIPTION OF SYMBOLS 1 ... 1st transparent or translucent thermoplastic resin sheet 2 ... Pattern pattern layer 3 ... Uneven shape 4 ... Melt extrusion thermoplastic resin layer 5 ... Adhesive layer or adhesive layer 6 ... Adhesive layer 7 ... Second transparent or translucent thermoplastic resin sheet 10 ... decorative sheet for decorative molding

Claims (6)

A pattern layer is provided on one surface of the first transparent or translucent thermoplastic resin sheet, an uneven shape is provided on the surface provided with the pattern layer, and a recess is filled on the surface provided with the uneven shape. a decorative molding decorative sheet provided with a melt-extruded thermoplastic resin layer, a deflection temperature under load of the first transparent or semi-transparent thermoplastic resin sheet of the load 1.80MPa is Ri range der of 120 to 160 ° C. ,
The deflection temperature under load of 1.80 MPa of the melt-extruded thermoplastic resin layer is 120 ° C. or higher, and the melt-extruded thermoplastic resin layer is formed on the first transparent or translucent thermoplastic resin sheet. decorative molding decorative sheet having internal irregularities deformation due to thermal behavior, characterized by the same or substantially the same der Rukoto. The decorative sheet for decorative molding having internal irregularities according to claim 1, wherein the first transparent or translucent thermoplastic resin sheet is polycarbonate. Said first transparent or semitransparent thermoplastic resin sheet is a coextruded film of polycarbonate and acrylic resin, according to claim 1 in which the outermost surface is characterized in that are stacked such that the acrylic resin Decorative sheet for decorative molding having internal irregularities. The decorative sheet for decorative molding having internal irregularities according to any one of claims 1 to 3 , wherein the melt-extruded thermoplastic resin layer is polycarbonate. Acrylic resin sheet as a second transparent or translucent thermoplastic resin sheet via an adhesive layer on the surface opposite to the surface provided with the pattern layer of the first transparent or translucent thermoplastic resin sheet A decorative sheet for decorative molding having internal irregularities according to any one of claims 1, 2, and 4 . A method for producing a decorative decorative sheet,
A step of providing a pattern layer on one surface of the first transparent or translucent thermoplastic resin sheet, a step of providing an uneven shape on the surface provided with the pattern layer, and a recess on the surface provided with the uneven shape. Providing at least a thermoplastic resin layer by a melt extrusion method so as to be filled,
The deflection temperature under load of 1.80 MPa of the first transparent or translucent thermoplastic resin sheet is in the range of 120 to 160 ° C.,
The deflection temperature under load of 1.80 MPa of the melt-extruded thermoplastic resin layer is 120 ° C. or higher, and the melt-extruded thermoplastic resin layer is formed on the first transparent or translucent thermoplastic resin sheet. A method for producing a decorative sheet for decorative molding, wherein the deformation due to thermal behavior is the same or substantially equivalent.

Images