JP6128854B2 - Manufacturing method of pneumatic molded products - Google Patents

Description

  The present invention relates to a method of forming a film or sheet, for example, a decorative hard coat sheet, into a desired three-dimensional shape by pneumatic forming under heating. More specifically, according to the present invention, the film or sheet has a substantially strain-free planar region that does not substantially shape, and the molded shaped product and the molded product have a planar portion. The present invention relates to a method for manufacturing a heat-shaped product and a sheet insert molded product.

  A decorative molded product (painted molded product) or an in-mold molded product has attracted attention from the aspects of productivity, design and functionality. Examples of applicable objects include exterior parts of mobile phones, automobile-related parts, medical equipment, electronics products, home appliances, building materials, containers such as detergents and cosmetics, and toys.

  As a method for obtaining such a molded product, a sheet insert molding in which a decorative film in which a printed layer having a predetermined pattern or character is formed on a base film is appropriately formed, mounted on a mold, and a resin is injected and solidified. The law is used. Typically, there is a method (painting molding) in which paper on which predetermined characters, patterns, etc. are printed is used as a base film. In addition, as a method of obtaining the above-mentioned molded product using plastics, a method of using a painted one after further shaping it into a predetermined three-dimensional shape, an acrylic layer on the surface and a polycarbonate on the back as an improved surface hardness Some use a coextruded sheet having a layer (Patent Document 1). In addition, a method (Patent Document 2) has been developed that uses a film or sheet having a hard coat on the surface and a design on the back as appropriate.

  At the time of thermoforming a coextruded sheet having an acrylic layer and a polycarbonate layer, the difference between the glass transition points of the two polymer layers is large, and a temperature sufficient to form a polycarbonate layer having a higher glass transition point is required. As a result, the acrylic layer having a lower glass transition point is overheated, and the surface of the acrylic layer is mainly roughened or a phenomenon in which distortion occurs occurs.

In the case of a plastic molded product having a transparent window portion or the like, the window portion or the like is required to have higher scratch resistance.
However, in the method using a hard coat film or sheet having a high surface hardness exceeding 4H, in addition to the property that the hard coat film is hard, the applied molded product has a gently curved surface. For some reasons, a film coated with a hard coat cannot be applied when a certain degree of elongation is required.

Therefore, a method of producing a molded product having a hard coat on a curved surface that requires elongation of a certain degree or more (for example, 30% or more) for shaping from a flat surface and a design on the back surface thereof,
(1) Forming a primary cured film that can be thermoformed on the surface and shaping it to a desired curved surface using a film or sheet having a predetermined design on the back surface, or directly curing the primary cured film into a mold A method of attaching and obtaining an insert molded product, and appropriately post-curing the primary cured film,
(2) Appropriately forming a hard coat primer layer on the surface and forming a film or sheet having a predetermined design on the back surface into a desired curved surface, or mounting the hard coat on the mold as it is, A method of obtaining an insert molded product and applying a hard coat as appropriate is considered, and development and improvement have been carried out.
Since both of these require a post-processing step on the shaped curved surface, there is a problem that it is a process with a poor yield, and further, the excellent productivity of the sheet insert molding method is achieved. There is a problem that it cannot be fully utilized.

  As one that does not have such problems, a decorative film is disclosed in which a design is applied to the back surface of a film on which a thermoformable hard coat layer is formed (for example, Patent Document 3). This example of Patent Document 3 discloses a film in which polyethylene terephthalate having a thickness of 125 μm is used as a base film and a specific hard coat layer having a thickness of 4 μm is formed on one side, and thermoforming at 180 ° C. Thus, it is disclosed that it can be processed into a three-dimensional shape of the curved surface portion R5 at 20 mm × 30 mm × 5 mm (vertical × horizontal × height) that needs to be bent or stretched.

  Naturally, the hard coat film of Patent Document 3 is inferior in terms of surface hardness, chemical resistance, and the like, compared to a conventional hard coat film that hardly requires thermoformability. Further, the hard coat film of Patent Document 3 is obtained by applying a hard coat to a polyethylene terephthalate (= PET) film. This PET film is biaxially stretched and subjected to a heat setting process. Further, the above-described molding at a thermoforming temperature of 180 ° C. is thermoforming at a temperature not higher than the heat setting temperature, the moldability is inferior, and it is difficult to apply to thermoforming having a smaller R than R5 and a larger local elongation. Met. PET that is not heat-fixed has a glass transition temperature as low as about 70 ° C., which causes a problem of heat resistance, and has high crystallinity, making it difficult to use as a transparent product. A stretched product that is not heat-fixed becomes a shrinkable film that rapidly shrinks above this glass transition temperature and is difficult to use. Of course, when a biaxially stretched product was heated to near the heat setting temperature, it contracted rapidly and was difficult to use.

  Moreover, there is a method of using a high molecular weight acrylic resin as a base film as a film having no problem in the thermoforming. However, when an acrylic resin is used for the base film, a defect such as cracking may occur when a process requiring a certain level of impact resistance such as punching is essential.

JP 7-156197 A JP-A-57-193331 JP 2010-284910 A

Select a co-extruded product of aromatic polycarbonate resin (PC) / acrylic resin (PMMA) as a sheet with good thermoformability, and use a hard-coated product on the PMMA resin surface. As a result of intensive studies to find a hard coat film obtained, a method for obtaining a three-dimensional shaped product that requires a large elongation, for example, 30% or more was found.
However, in the case where a portion that requires such a large elongation and a portion that does not need to be distorted, such as a flat transparent window portion, are included, a method that does not cause distortion in the portion that is not shaped is desired. Mareta.
As a result of diligent examination regarding this method, it was confirmed that, under the application of normal conditions (infrared heating, pneumatic shaping conditions), the portion using the infrared shielding layer or the like was not shaped and no distortion occurred. The present invention has been completed.

  That is, the present invention is as follows. (1) In a method for manufacturing a shaped product in which a film or sheet is heated by infrared heating to be pneumatically formed, the shaped product includes a flat portion, and the flat region of the film or sheet corresponding to the flat portion In the manufacturing method of a shaped article, a heating suppression region is provided in the heating suppression region, and heating is suppressed in the heating suppression region as compared with a peripheral region of the heating suppression region.

(2) The method for producing a shaped article according to the above (1), wherein the heating suppression region is an infrared reflecting layer and / or an infrared shielding heat insulating layer.
(3) In the said heating suppression area | region, it is a manufacturing method of the shaped article of the said (1) description provided with the transfer area | region which changed the degree of the heating suppression in steps or continuously.
(4) The method for producing a shaped article according to (1), (2), or (3), wherein the heating suppression region is formed on a transparent protective film temporarily bonded to the film or sheet. It is.
(5) The method for producing a shaped article according to the above (1), wherein the local maximum elongation of the film or sheet accompanying heat molding is 30% or more.
(6) In the scratch resistance test of the hard coat surface of the film or sheet (according to ASTM D 2486-79, using a pig hair brush and 200 reciprocations at a load of 450 g), the number of scratches generated is 10 or less (1 ) Is a manufacturing method of the shaped article.

The present invention is as follows.
(7) A film or sheet is heated by infrared to produce a molded product by pneumatic molding, the molded product is directly or punched and mounted on a mold, and a thermoplastic resin is injected and integrated on the back surface of the molded product. In the sheet insert molded product manufacturing method, the molded product includes a flat portion, and a heating suppression region is provided in the planar region of the film or sheet corresponding to the planar portion, and in the heating suppression region, It is a manufacturing method of a sheet insert molded article characterized by suppressing heating more than the peripheral area of the heating suppression area.
(8) The method for producing a shaped product or a sheet insert molded product according to (1) or (7) above, wherein the film or sheet is heated by infrared rays and is subjected to pressure air molding with pressurized air.
(9) The method for producing a shaped article or a sheet insert molded article according to (1) or (7), wherein the film or sheet has a design on the back surface opposite to the hard coat surface.
(10) The method for producing a shaped article or a sheet insert molded article according to (1) or (7), wherein the film or sheet is heated with the hard coat surface of the sheet or outer sheet as an outer surface.
(11) The coating according to (1) or (7), wherein the film or sheet is a co-extruded product of an aromatic polycarbonate resin and an acrylic resin, and the hard coat surface is formed on the acrylic resin layer. This is a manufacturing method of a molded product or a sheet insert molded product.
(12) The shaped article according to (1) or (7), wherein the film or sheet has a hard coat surface, and the shaped article or the molded article includes a flat portion in a hard coat layer. Or it is a manufacturing method of a sheet insert molded article.

  By using a film or sheet provided with a heat-suppressing region, a region that should not be shaped during heating shaping is not substantially shaped and the original good surface state is maintained as it is. A shaped product and a sheet insert molded product were obtained by using this shaped product.

FIG. 3 is a perspective view showing a sheet of Example 1. 10 is a perspective view showing a sheet of Example 3. FIG. It is a top view which shows the heat ray reflective layer containing the transfer area | region of Example 2. FIG. It is a perspective view which shows the sheet insert molded product of Example 5. FIG.

The configuration and the like will be described below with respect to the present invention.
In the present invention, when a film or sheet described below, for example, a multilayer sheet (hereinafter, appropriately referred to as a multilayer sheet or the like) is produced as a heat-shaped product having a desired three-dimensional shape, the shaped product is free from distortion. When a flat part is included, a molded article including a flat part substantially free from distortion and roughness is produced by providing a heating suppression region in the film or sheet part corresponding to the flat part.

1. Film or sheet (multilayer sheet)
As a sheet or a multilayer sheet (hereinafter, appropriately referred to as a multilayer sheet or the like) used for production of a molded article or the like of the present invention,
(1) Transparent sheet using transparent plastic material,
(2) A transparent multilayer sheet in which a resin having impact resistance and moderate heat resistance is used as a base layer, and a hard resin layer is formed on one or both sides thereof, and
(3) A multilayer sheet in which a hard coat layer is formed on one side or both sides of the sheet of (1) or (2).

1-1. In the present invention, the transparent plastic material (1) used for the multilayer sheet and the like includes aromatic polycarbonate, amorphous polyolefin (typical example: alicyclic polyolefin), polyacrylate, polysulfone, and acetylcellulose. , Polystyrene, amorphous polyester (typical example: PET-G), transparent polyamide, and the like, and transparent resins made of these compositions. Of these, resins used for optics are preferred, and are aromatic polycarbonate, (meth) acrylic resin, styrene- (meth) acrylic copolymer resin, hydrogenated styrene- (meth) acrylic copolymer resin (of styrene component). Examples include hydrogenated benzene rings to partially alicyclic rings) and transparent polyamides.

  Aromatic polycarbonate (PC) includes 2,2-bis (4-hydroxyphenyl) alkane and 2,2- (4-hydroxy-) in terms of impact resistance, strength, heat resistance, durability, and bending workability. A polymer produced by a well-known method from a bisphenol compound represented by 3,5-dihalogenophenyl) alkane is preferred. The polymer skeleton may contain a structural unit derived from a fatty acid diol or a structural unit having an ester bond. In particular, an aromatic polycarbonate derived from 2,2-bis (4-hydroxyphenyl) propane is used. preferable.

As an amorphous polyester resin, for example, a dicarboxylic acid component typified by 1,4-cyclohexanedicarboxylic acid, a diol component typified by 1,4-cyclohexanedimethanol, and other small amounts of components as required May be obtained by a known method in which an esterification or transesterification reaction is carried out, and then a polymerization catalyst is added as appropriate, and the pressure in the reaction vessel is gradually reduced to cause a polycondensation reaction.
Specific examples of alicyclic dicarboxylic acids or ester-forming derivatives thereof include 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, and 1,4-decahydronaphthalene. Examples thereof include dicarboxylic acid, 1,5-decahydronaphthalenedicarboxylic acid, 2,6-decahydronaphthalenedicarboxylic acid, 2,7-decahydronaphthalenedicarboxylic acid, and ester-forming derivatives thereof.

  Polyamide resins that can be used in the present invention include those known as optically transparent polyamide resins, which have a heat distortion temperature of 100 to 170 ° C., which is an index of heat resistance, and are aromatic polyamide resins and alicyclic rings. Aliphatic polyamide resins, aliphatic polyamide resins, and copolymers thereof, and alicyclic polyamide resins are preferred from the balance of mechanical strength, chemical resistance, transparency and the like. A polyamide resin may be combined. Examples of such polyamide resins include, but are not limited to, GLILAMIDTR FE5577, XE 3805 (manufactured by EMS), NOVAMID X21 (manufactured by Mitsubishi Engineering Plastics), and Toyobo Nylon T-714E (manufactured by Toyobo).

  As the polyacrylate, the above-mentioned (meth) acrylic resin, styrene-acrylic copolymer resin, hydrogenated styrene- (meth) acrylic copolymer resin and the like can be used (same as above). As the (meth) acrylic resin, polymethyl methacrylate (PMMA), homopolymers of various (meth) acrylic esters represented by methyl methacrylate (MMA), or PMMA, MMA and one or more other single monomers It may be a copolymer with a body, and a mixture of a plurality of these resins may also be used. Among these, (meth) acrylates having a cyclic alkyl structure excellent in low birefringence, low hygroscopicity, and heat resistance are preferable. Examples of such (meth) acrylic resins include Acrypet (TM) manufactured by Mitsubishi Rayon Co., Ltd., Delpet (TM) manufactured by Asahi Kasei Chemicals Corporation, and Parapet (TM) manufactured by Kuraray Co., Ltd. Although there is, it is not limited to these.

The base material layer of the transparent multilayer sheet of (2) is a layer for maintaining basic physical properties, and the resin used in the above is aromatic polycarbonate, aromatic polycarbonate and amorphous polyester resin. A composition is mentioned as a representative example because of its high impact resistance.
As a hard resin layer (described later) to be formed on one side or both sides of this base material layer, an acrylic resin, a copolymer of a (meth) acrylic acid ester monomer and an aromatic vinyl monomer (hereinafter referred to as MS resin), A resin obtained by hydrogenating the aromatic ring of this MS resin (hereinafter referred to as a nuclear hydrogenated MS resin), an aromatic polycarbonate resin copolymerized with 2,2- (4-hydroxy-3-methylphenyl) alkane, and the like; Examples thereof include a composition of an acrylic resin obtained by copolymerizing an acrylic monomer having an aromatic ring that is compatible with an aromatic polycarbonate resin, and an aromatic polycarbonate resin, and an acrylic resin and a nuclear hydrogenated MS resin are preferred.
From the viewpoint of improving weather resistance, these are usually used as compositions containing an ultraviolet absorber.

1-2. Plane area (plane part)
The multilayer sheet or the like includes, for example, a transparent display window portion or a portion used as a scale as a flat region without distortion. The planar area of the multilayer sheet or the like needs to form a planar portion free from distortion and unevenness even in a shaped product, an insert molded product or the like manufactured by pneumatic molding. For this reason, in this invention, a heating suppression area | region is provided in planar areas, such as a multilayer sheet, ie, the area | region corresponded to planar parts, such as a shaped article. By forming these infrared reflection layers, or infrared shielding heat insulating layer, during infrared heating, it is possible to prevent infrared rays from being directly irradiated to a planar area such as a multilayer sheet, compared to the area around the planar area, The effect which suppresses and delays the heating with respect to a plane area | region is acquired. Details of the heating suppression region will be described later.

  In order to improve the smoothness of the flat part of the shaped product and insert molded product produced in the present invention, the planar region of the multilayer sheet is substantially free from distortion and unevenness, for example, surface roughness. Ra is 0.2 μm or less, more preferably 0.1 μm or less.

1-3. Shape and Properties of Multilayer Sheet, etc. The sheet or multilayer sheet used in the present invention is usually produced by an extrusion method or a coextrusion method, and the thickness is appropriately selected from the range of 0.1 mm to 1.0 mm, preferably 0.8 mm or less. .
In the case of a multilayer sheet, the thickness of the hard resin layer formed on one or both sides of the base sheet is preferably less than half of the thickness of the multilayer sheet, and the thickness of the hard resin layer is preferably selected from 0.03 mm to 0.1 mm Is done. If it is too thin, the pencil hardness and the like are not preferable, and if it is too thick, the effect of increasing the hardness is lost and the characteristics of the base material layer are greatly deteriorated.
The multilayer sheet or the like (film or sheet) used in the present invention has a local maximum elongation value of 30% or more accompanying heat molding.

1-4. Hard coat layer (hard coat surface)
The hard resin layer (hard coat layer) is appropriately hard coated in the extrusion step or after being extruded. Usually, those excellent in wear resistance and fingerprint resistance (fingerprint wiping) are preferable, but since it is essential to give a desired three-dimensional shape by thermoforming, desired thermoformability, In particular, a hard coat that exhibits elongation is selected.

A hard coat layer such as a shaped article produced according to the present invention is formed by a hard coat surface such as a multilayer sheet used as a material. As the material of the hard coat surface (layer), a compound that forms a known cross-linked film such as acrylic, silicon, melamine, urethane, and epoxy can be used. As the curing method, a known method such as ultraviolet curing, thermal curing, electron beam curing or the like can be used. Among these, the surface to be used as the surface side is preferably one having a pencil hardness of H or higher and a steel wool hardness of 7 or higher, and an acrylic type is exemplified from the viewpoint of balance with heat formability.
The hard coat layer may be applied by an ordinary method, such as a coating method such as a roll coating method, a dip method, or a transfer method.
In some cases, a hard coat layer may be formed using any of the methods described above after thermoforming a multilayer sheet without a hard coat, for example, a PC / PMMA multilayer sheet.

In particular, the hard coat layer is preferably excellent in extensibility, and specifically, it preferably exhibits a local maximum elongation of 30% or more, more preferably 35% or more. The value of local maximum elongation here is measured as follows. First, a dumbbell piece made of a hard coat film with a marked line is pulled and stretched using a tensile tester, and the distance between marked lines of the obtained sample is measured at the last pulling amount at which the hard coat is not broken. And elongation rate (%) is computed by the following formula | equation.
Elongation rate (%) = (Dimension between stretched marked lines−Dimension between initial marked lines) / Dimension between initial marked lines In this way, it is calculated based on the measurement result under the maximum pulling amount at which the hard coat does not break. The value of the elongation rate (%) is defined as the above-mentioned local maximum elongation.
For the formation of the hard coat layer, paints appropriately selected from those showing a known commercial elongation for PET, or based on this, subcomponents such as solvent systems are changed so that they can be applied to this multilayer sheet. Can be used.
The thickness of the hard coat layer is adjusted mainly by adjusting the solid content concentration of the hard coat paint. The thickness of the hard coat layer is usually in the range of 0.0005 mm to 0.01 mm, preferably 0.001 mm to 0.005 mm.

The hard coat paint exhibiting elongation is preferably a normal UV-curable paint component having a long-chain component (a) having a number average molecular weight of several hundred to several thousand for crosslinking, and crosslinking It consists of an essential component mixed with (meth) acrylate component (b) having an average of 3 to 8 (meth) acryloyl groups which increase the density and mainly impart hardness. Although there is a range of performance depending on the reaction rate of the functional group when forming the hard coat layer, the balance between the elongation and hardness of the hard coat is mainly determined by the ratio of the above (a) and (b). .
In addition, since the hard coat which shows elongation also consists of a crosslinked structure, it is not usually deteriorated except for the opening reaction of the crosslinked bond. However, the network of the crosslinked structure of the hard coat layer is gentle in order to maintain the elongation. An organic chemical or the like changes in time according to the size of the mesh and the size of its own molecule, but penetrates into the hard coat layer and reaches the base film. Therefore, it is preferable that the base film has high temperature and long-term chemical resistance.

The long chain component (a) having a number average molecular weight of several hundred or more to several thousand is the both ends obtained by reacting an aliphatic or alicyclic diol with a compound having two isocyanato groups. And other diisocyanates having an isocyanato group; di (meth) acrylates having (meth) acryloyl groups at both ends obtained by reacting this diisocyanate with a (meth) acrylate having a dihydroxy group.
Examples of the diol include aliphatic dihydroxy compounds having a structure such as a straight chain, branched chain, and alicycle having 2 to 10 carbon atoms, polyoxyalkylene glycols such as polyethylene glycol and polypropylene glycol, and oligomers or medium molecular weights such as polyester diols. Such as things.
Examples of the aliphatic or alicyclic diisocyanate include aliphatic diisocyanates having 8 to 15 carbon atoms such as 1,6-hexamethylene diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate, lysine diisocyanate, isophorone diisocyanate, 4 4,4'-dicyclohexylmethane diisocyanate, 1,4-cyclohexane diisocyanate, norbornane diisocyanate, and the like.

Here, the (meth) acrylate of the component (b) means a compound having an acryloyl group or a methacryloyl group. The (meth) acrylate may be any of a monomer, an oligomer, and a prepolymer. The (meth) acrylate may be monofunctional, difunctional or higher polyfunctional, may have a polar group, or may have a low polar molecular structure.
Examples of the polar group include a hydroxyl group, a carboxyl group, an amide group, an amino group, and the like, and those having a plurality of one or more types can be suitably used. For example, the hydroxyl group of (meth) acrylate ((meth) acrylamide) having a hydroxyl group is suitable for reaction with isocyanate, and is also used for the preparation of the component (a).

The component (b) has 3 to 8 (meth) acryloyl groups. These components may be used alone or in combination of two or more, but it is usually preferred to use a combination of many types.
The molecular structure of the portion to which these (meth) acrylate groups are bonded is one having at least one kind of straight chain, branched chain, alicyclic ring or aromatic ring in the structure, a bonding structure such as ether, ester, urethane, amide, and the like. The thing oligomerized by the silicone chain etc. is illustrated.

  Reaction between glycol and aliphatic diisocyanate, reaction between urethane prepolymer and hydroxy group-containing (meth) acrylate or hydroxy group-containing (meth) acrylamide, aliphatic polyisocyanate and hydroxy group-containing (meth) acrylate or hydroxy group-containing (meta The reaction with acrylamide and the reaction between diol and dicarboxylic acid can be carried out by known methods.

  If necessary, a photopolymerization initiator, other additives, and a solvent are mixed with the above components to form a hard coat paint. Examples of the photopolymerization initiator include benzophenone, benzyl, Michler's ketone, 2-chlorothioxanthone, 2,4-diethylthioxanthone, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, 2,2-diethoxyacetophenone, benzyldimethyl ketal, 2 , 2-Dimethoxy-1,2-diphenylethane-1-one, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, 2-methyl-1- [4- ( Methylthio) phenyl] -2-morpholinopropanone-1, 1- [4- (2-hydroxyethoxy) -phenyl] -2-hydroxy-2-methyl-1-propan-1-one, bis (cyclopentadienyl) ) -Bis (2,6-difluo) -3- (Pyr-1-yl) titanium, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone-1,2,4,6-trimethylbenzoyldiphenylphosphine oxide, etc. These compounds are used alone or in combination.

The amount of the photopolymerization initiator used is 0.1 to 7% by weight, preferably 0.1 to 5% by weight, based on the total solid content of the hard coat layer. If it is less than 0.1% by weight, the photocurability is lowered, and if it exceeds 7% by weight, it may be colored, and the progress of the curing reaction does not change.
Moreover, in order to improve photocurability, various well-known dyes and sensitizers can be added. Furthermore, a thermal polymerization initiator can be used in combination.
Depending on the situation, surfactants such as leveling agents, antifoaming agents, and antifouling agents, additives such as surface modifiers, and fillers such as organic fillers and inorganic fillers may be added to the hard coat layer. it can.

  In the manufactured shaped product and the molded product, it is required that the hard coat layer is not easily damaged. For this reason, it is preferable that hard coat surfaces, such as a multilayer sheet, are excellent in abrasion resistance. More specifically, in a scratch resistance test (according to ASTM D 2486-79, using a pig hair brush and 200 reciprocations at a load of 450 g), a hard coat surface having 10 or less, preferably 5 or less scratches is generated. The multilayer sheet etc. which have are used.

1-5. Design properties of multilayer sheets etc. The multilayer sheets used in the present invention are usually given a design. That is, it has a design printing layer or a metal vapor deposition layer on the back surface opposite to the hard coat surface such as a multilayer sheet. In the present specification, “design is applied” means that a decoration such as letters, numbers, symbols, patterns, etc. can be visually recognized from the outside of a shaped product or a molded product, It means that a layer such as a vapor deposition layer is formed, or that the decoration is printed on a multilayer sheet or the like.
The multilayer sheet or the like used in the present invention preferably has a hard coat layer on the back surface from the viewpoint of handleability, printing on the back surface, and suitability for metal vapor deposition.
Since the sheet having a thickness of 0.5 mm or more has high rigidity, the printed layer or the like can be used by directly sticking it to a molded product or a cut product with an adhesive or the like.
In the case of 0.5 mm or less, it is usually used integrally with the injection molding material. On the back side of the multilayer sheet or the like, a hard coat layer / printing layer or a metal vapor deposition layer is formed on the base resin, and an injection molding resin is placed thereon and heat-sealed. From this point, it is preferable that the printing ink is firmly bonded to the hard coat layer and is also firmly heat-sealed with the injection resin. In addition, when there is a portion with insufficient heat-fusibility with the injection resin, for example, when a hard coat layer portion without a print layer or a metal vapor deposition layer is in contact with the injection resin, selecting the molding conditions, For example, although the heat-fusibility is improved by increasing the resin temperature, etc., it is usually necessary to form a heat-fusable primer layer on these layers with insufficient heat-fusibility. preferable. In addition, the primer layer (For example, IMB binder by Teikoku Ink Manufacturing Co., Ltd.) can be used as this primer layer.

The ink used to form the design pattern on the back side of the multilayer sheet can be used if it can be in close contact with the polycarbonate resin unless it is integrated with the injection molding material, but can be integrated with the injection molding material. In this case, it is necessary to select an ink that is difficult to be softened even by the heat of the injection molding material. The following are exemplified.
When not integrated with injection molding material, Teikoku Mfg. Co., Ltd. FMX, ISX, MRX, IPX series, when integrating with injection molding material, IPX series.

  As the above-mentioned injection molding resin, polycarbonate (PC), ABS, PC / ABS, PMMA, HIPS and the like can be used.

1-6. Protective film As the protective film (masking film) to be attached to the surface of the multilayer sheet used in the present invention, a polypropylene-based masking film having heat resistance of 100 ° C or higher is suitable. Moreover, the masking film which does not use the adhesive produced by two layers is further suitable. The outer surface of a multilayer sheet or the like, that is, the hard coat, or the surface layer in contact with the resin layer on the surface side is easily welded by heat at the time of extrusion molding, so by selecting a protective film that does not use an adhesive, There is also an effect that the adhesive does not easily remain on the surface. Furthermore, since the surface side of the protective film has heat resistance, it also has an effect of preventing alteration due to heat.

In terms of heat resistance, there is masking made of PET film, but it is difficult to bend in thermoforming, and since the adhesive is not heat resistant, it can easily remain, so it is difficult to handle in this application.
Masking films suitable for the present application include VLH series manufactured by Tosero Co., Ltd. or K series manufactured by DIC Corporation.
In addition, although a multilayer sheet is heated to about 200 degreeC, since a heating time is short even if a raw material is a polypropylene, it does not reach until it melts, Therefore It can be used as a protective film. In addition to polypropylene-based protective films, protective films such as polyvinyl chloride and polyethylene can be used.

  It is preferable that the molding process of the multilayer sheet or the like is performed in a state where such a protective film is temporarily bonded onto the outer surface of the multilayer sheet or the like, for example, the hard coat surface. In this case, it is preferable that the above-described heating suppression region is formed on the protective film.

1-7. Molded Article In the method for producing a sheet insert molded article of the present invention, first, a molded article such as a multilayer sheet is produced as described above, and the molded article is mounted on a mold and a thermoplastic resin is attached to the back side thereof. Manufactures a sheet insert molded product formed by injection integration. A molded product such as a multilayer sheet includes a flat portion, and a heating suppression region is provided in a flat region of the film or sheet corresponding to the flat portion. The details of the planar region (planar part) such as the multilayer sheet are as described above, and the heating suppression region will be described later.

1-8. Thermoplastic resin In the method for producing a sheet insert molded product, there is no particular limitation on the type of thermoplastic resin integrated with the molded product such as a multilayer sheet, and polymethyl methacrylate or the like is preferably used.

2. Next, a description will be given of the point that the multilayer sheet or the like is thermoformed to obtain a desired three-dimensional shape.
A typical method of thermoforming in the present invention is to apply a design pattern or the like on the back surface of a multilayer sheet, set the outer surface hard coat surface or, for example, a PMMA surface on the mold, and rapidly heat by infrared heating. Heat up to the thermoforming temperature above the glass transition temperature of the multilayer sheet base material resin, and press against the mold surface set below the glass transition temperature of the polycarbonate resin with pressurized air, for example, to form a predetermined three-dimensional shape To do.

2-1. Infrared heating The heating temperature by infrared rays is a temperature range not higher than 110 ° C., preferably not higher than 90 ° C. from the glass transition temperature of the surface layer side resin such as the hard coat surface, and higher than the glass transition temperature of the base layer resin. Preferably, a temperature range of 5 ° C. or higher, particularly a temperature range of 10-60 ° C. or higher is preferable.
If the heating temperature on the hard coat surface side is too high, cracks will occur in the hard coat surface in a short time when pressed against the mold surface with pressurized air, etc., and the heating temperature of the base layer resin will be If it is too low, the elongation will be insufficient and the transfer rate of the mold surface shape will decrease, or cracks will occur. As described above, the heating temperature is adjusted depending on the material of the material such as the multilayer sheet, but when PC / PMMA is used, it is generally 160 to 220 ° C, preferably 180 to 200 ° C.

2-2. Heating suppression The above-described heating suppression region (see section 1-2.) Will be described below. The heating suppression region suppresses or delays heating of the planar region such as a multilayer sheet in order to reliably form a smooth planar part. As the heat suppression region, an infrared reflective layer and / or an infrared shielding heat insulating layer, specifically, a printing layer excellent in infrared reflectivity, usually a white ink printing layer, an adhesive tape capable of thermal shielding, etc. Pasting is exemplified. More specifically, a resin layer made of polypropylene or the like, a paper tape, or the like.

As the above-mentioned adhesive tape, for example, an adhesive resin layer formed on a release film or the like, an adhesive component impregnated and attached to a support, and appropriately dried to remove volatile components. is there.
Although a uniform film can be used as the support depending on the method of use, paper and cloth, particularly nonwoven fabric are preferable, and paper and cloth using polyester and polyimide, particularly nonwoven fabric and paper are preferable.
In addition, as the pressure-sensitive adhesive, a material that does not foam with a volatile component even when it comes into contact with a high-temperature resin is selected, and since it remains on the molded product or the masking film as it is, a component that changes as it is (such as curing) In this case, a component that does not promote deterioration is selected. There are rubber, acrylic, and silicone types of pressure-sensitive adhesives, and these are applied and impregnated as liquids in organic solvent solutions, emulsions, hot melts, and other methods, excess organic solvents, water, etc. Is appropriately removed to obtain an adhesive sheet. In the present invention, acrylic is more preferable, and the volatile components are not exposed to high temperatures or little.
Even a double-sided tape with paper that is generally sold can be used.

The effect of suppressing and delaying heating with respect to the planar area obtained by setting the heating suppressing area is particularly useful in the following cases.
When a thermoformed mold having a large rising height is used and a shaped product having a flat portion without distortion in the present invention is formed thereon, and a molded product is produced, a large stretch is produced around the flat portion that is not stretched. The required part will be located. The corner portion is formed by stretching in two directions. Further, the area around the rise or near the root does not require any elongation.
In order to make such a shaped product free from distortion and roughness, it is particularly preferable to devise a method for reducing the cause of distortion and roughness by controlling the heating state according to the site of the multilayer sheet. For this reason, in this invention, a heating suppression area | region is provided in planar areas, such as a multilayer sheet corresponded to the planar part of a shaped article, and a heating is suppressed and delayed compared with the area | region around a heating suppression area | region.

  More specifically, in this invention, the heating temperature in the plane part in which the heating suppression area | region was formed is suppressed below to the glass transition temperature of base resin, for example, 145 degrees C or less. And said heating suppression area | region is normally formed on the protective film stuck on the hard-coat layer or PMMA layer mentioned later.

  In addition, in the vicinity of the heating suppression region, that is, in contact with the peripheral region where heating is not suppressed, or in a part of the heating suppression region in the vicinity of the peripheral region, the heating suppression of the peripheral region side is performed stepwise or continuously. It is preferable to provide a transition region in which the degree is changed. In the transition region, heating is gradually suppressed from the peripheral region side where heating is not suppressed toward the center side of the planar region side where heating is suppressed.

  As described above, the transition region to be used as appropriate can be theoretically formed by any of the examples of the heating suppression region, but it is more practical to form it as a gradation print pattern. By providing the transition region, the surface difference due to heating between the planar region such as the multilayer sheet and the shaped part boundary can be blurred, and the center side of the heating suppression region having a large distance from the peripheral region that does not suppress heating By suppressing the heating as much as possible, it is possible to further improve the overall finish of the finished shaped article or the like.

2-3. Pneumatic forming In the present invention, preferably, a multilayer sheet or the like is pressed against a mold using pressurized air. However, instead of using compressed air to press the multilayer sheet or the like against the mold, the multilayer sheet or the like may be brought into close contact with the mold by reducing the pressure to the vacuum level, and heated or vacuum formed. good. Alternatively, vacuum forming may be used in combination with the above-described compressed air forming using the pressurized air.

  The pressure of pressurized air used for forming a multilayer sheet or the like is 0.5 to 10 MPa, preferably about 1 to 5 MPa, and the degree of reduced pressure in vacuum forming is about -0.1 MPa to -0.05 MPa.

3. Shaped product and insert-molded product According to the method for producing a shaped product of the present invention, for example, the above-mentioned multilayer sheet or the like (film or sheet) having a hard coat surface is heated by infrared heating and subjected to pneumatic molding, and shaped. Shapes are manufactured. In addition, a heating suppression region is provided in a planar region such as a multilayer sheet that forms a planar portion in the hard coat layer of the shaped product, and heating is suppressed in the heating suppression region more than the peripheral region of the heating suppression region. , Delay. As a result, the surface portion of the shaped product is excellent in smoothness.

  More specifically, the flat part of the shaped product is substantially free from distortion and unevenness, for example, the surface roughness Ra of the flat part is 0.2 μm or less, more preferably 0.1 μm or less. . The same applies to the flat portion of a sheet insert molded product manufactured by another manufacturing method of the present invention.

  Hereinafter, an example of the present invention will be described with reference to examples.

The raw materials used in Examples and Comparative Examples are as follows.
PC: Aromatic polycarbonate (Manufacturer: Mitsubishi Gas Chemical Co., Ltd., product number: E2000, with a molecular weight of about 28000 manufactured from bisphenol A)
PMMA: Polymethylmethacrylate (manufacturer: Ryokan Co., Ltd., product number: VH001)
Copolymer of methyl methacrylate / methyl acrylate = 95.6 / 4.4
Weight average molecular weight (Mw) by styrene column GPC 85,000
HC1: Hard coat paint that stretches
Unidic EKC-578 (manufactured by DIC Corporation) (urethane acrylate)
HC2: Hard coat that does not stretch and hard Product name: XR39-5095 Momentive Performance Materials Japan GK)

Examples 1 to 4 and Comparative Examples 1 and 2
As the above-mentioned aromatic polycarbonate resin extruder, a barrel diameter of 65 mm and a screw L / D = 35 were used, and the cylinder temperature was 270 ° C.
Further, as the above-mentioned PMMA extruder, a barrel diameter of 32 mm and a screw L / D = 32 were used, and the cylinder temperature was 250 ° C.

When two types of resins were melt-extruded and laminated at the same time, a feed block was used, and the PMMA layer 14 made of PMMA was laminated on one side of the PC layer 12 of the aromatic polycarbonate resin (see FIG. 1).
The temperature inside the die head was 260 ° C., and the resin laminated and integrated in the die was guided to three polishing rolls having a mirror finish and molded. At this time, the temperature of the first roll was set to 110 ° C., the temperature of the second roll was set to 140 ° C., and the temperature of the third roll was set to 180 ° C., respectively.
A bank was formed at the first inflow roll interval, and then a coextruded sheet was produced by passing the second and third rolls (hereinafter referred to as an RS sheet). In the process of sending the RS sheet while being cooled, a masking film (VLH-6 manufactured by Tosero Co., Ltd.) was attached to both sides of the sheet at a position where the temperature reached 90 ° C. The thickness of the manufactured RS sheet 10 of Example 1 was 0.5 mm, the PC layer 12 was 0.46 mm, the PMMA layer 14 was 0.04 mm, and the thickness of the masking film (not shown) was 0.02 mm. .

  After peeling off the masking film from the outer surface 14S of the PMMA layer 14 of the above-mentioned 0.5 mm thick RS coextruded sheet 10 (PMMA layer thickness 0.04 mm) with the masking film attached on both sides, the above-mentioned extension is performed on the PMMA surface 14S. After the coating film was applied with a hard coat paint (HC1) with a bar coater, it was cured with UV to form a hard coat layer 28 (hereinafter this sheet is referred to as E-HC sheet 20 of Example 3; see FIG. 2). 2 corresponds to the PMMA layer 14 and the outer surface 14S of FIG. 1, respectively). Again, immediately after curing, the masking film was attached with a laminator in which a rubber roll was heated to 90 ° C. This HC film had a thickness of 5 μm, a pencil hardness of 2H, and an abrasion resistance test (according to ASTM D 2486-79, using a pig hair brush and 200 reciprocations at a load of 450 g), and produced no more than 4 scratches.

The masking of the PC surfaces 12S and 22S (surfaces of the PC layers 12 and 22) of the RS sheet 10 of Example 1 and the E-HC sheet 20 of Example 3 is removed, and printing is performed on the surface (back surface). (Ink; IPX-HF manufactured by Teikoku Ink Manufacturing Co., Ltd.) was applied (only the central 50 mm square was not printed).
A transparent binder ink (IMB006 binder manufactured by Teikoku Ink Manufacturing Co., Ltd.) was applied thereon. The thickness of the transparent binder ink layer (not shown) was 0.006 mm. On the masking film of the hard coat layer 28 laminated on the PMMA surface (outer surface 14S) or the PMMA surface (outer surface 24S), a thickness of 0.1 mm is punched into a 68 mm square so as to match the center of the screen (planar region) at the center. mm paper gum tapes (manufactured by Sekisui Chemical Co., Ltd.) were bonded to form the heat ray blocking layers 16 and 26, respectively.
In this way, samples having the heat ray blocking layers 16 and 26 were respectively prepared (Example 1 (RS sheet 10) and Example 3 (E-HC sheet 20), see Table 1, which will be described later, FIG. 1 and FIG. 2). . Further, instead of the heat ray blocking layers 16 and 26 described above, a heat ray reflective layer was formed as follows, and the sheets of Examples 2 and 4 were formed.
1) On the masking film on the PMMA surface (outer surface 14S) of Example 1, a 68 mm square area (65 to 68 mm area is dot-type gradation printing) so as to match the center of the screen (planar area) in the center. After printing ink (white) (MRX manufactured by Teikoku Mfg. Co., Ltd.) was applied by printing, it was cured at 90 ° C. for 30 minutes to provide a 10 μm heat ray reflective layer 36 of Example 2 (see FIG. 3). The heat ray reflective layer 36 was similarly provided on the masking film of the hard coat layer 28 of Example 3.
In this way, samples having the heat ray reflective layer 36 instead of the heat ray blocking layers 16 and 26 in Examples 1 and 3 were prepared (Example 2 (RS sheet) and Example 4 (E-HC sheet), Neither is shown). In Example 2, as shown in FIG. 3, an area of 65 mm to 68 mm that is dot-type gradation printed on the outer edge of the heat ray reflective layer 36 is a transition area 37. Continuously, the degree of heating suppression changes. That is, in the transition region 37, the dot density gradually increases from the peripheral region 38 side where heating is not suppressed toward the screen center point C on the plane region side, and heating is suppressed toward the center side of the plane region. (The same applies to Example 4).
2) Moreover, the sample of which neither the heat ray blocking layer nor the heat ray reflective layer was formed without performing the above-described step 1) was produced (Comparative Example 1 (RS sheet) and Comparative Example 2 (E-HC sheet). ), Neither is shown).

Subsequently, pressure forming was performed using these film samples.
Molding machine: Pressure forming machine (manufactured by NK Enterprise Co., Ltd.).
IR heater; 360 ° C setting Far-infrared heater (peak wavelength at 2500 nm) Near-infrared is also generated.
Temperature measurement: Heated with upper IR heater. An infrared radiation thermometer is installed on the lower side to measure the film temperature.
Mold: convex shape with 70mm square, ridgeline 1R, core height 4mm.
Molding: When the film temperature other than the screen portion (planar region) reached 190 ° C., the film moved to the mold clamping zone, and after mold clamping, compressed air was blown in at 2 MPa for 5 seconds, and then the mold was opened to take out the molded product. In addition, the temperature of the screen part (plane area | region) with a heat ray shielding layer and a heat ray reflective layer was 145 degreeC.
The masking of the PMMA surface or hard coat was removed, and the screen portion appearance and screen portion surface roughness of the PMMA surface or hard coat surface were evaluated.
Observation of molded product surface condition (screen appearance) (visual);
○: The surface is not roughened, and the occurrence of distortion is not confirmed.
X: The surface is roughened or distortion is confirmed.
Screen surface roughness measurement;
Surface roughness Ra was measured based on ISO4288 (equipment used: foam tracer S-VC4500 manufactured by Mitutoyo Corporation).

Examples 5 and 6 and Comparative Example 3
After removing the mask on the PMMA layer 14 side from the RS sheet formed by pressure forming obtained in Examples 1 and 2 and Comparative Example 1 above, the HC liquid (HC2) was applied by spray coating. And cured with UV (hereinafter RS-HC sheets of Examples 5 and 6).
The HC film (for example, the hard coat layer 48 of FIG. 4 showing the RS-HC sheet 40 of Example 5) in these RS-HC sheets has a thickness of 5 μm, a pencil hardness of 7H, and an abrasion resistance test (ASTM D 2486-79). In accordance with the above, the number of scratches generated was 0 when using a pig hair brush and reciprocating 200 times at a load of 450 g. Further, in Example 5, a heat ray blocking layer 46 similar to the heat ray blocking layer 16 of Example 1 is formed on the hard coat layer 48, and in Example 6, the heat ray reflective layer 36 of Example 2 of FIG. Heat ray reflective layers similar to those described above were formed on the hard coat layer (see Example 5 for the hard coat layer 48 in FIG. 4 and Example 6 not shown).

  Using the RS-HC sheets of Examples 5 and 6 above, each was stamped into an injection mold shape (71 mm square) with a press, inserted into an injection mold, and PMMA resin (acrylic VRL40 diamond) as an injection molding material. Using an injection molding machine (J100AD manufactured by Nippon Steel), and injection molding is performed at a resin temperature of 290 ° C and a mold temperature of 60 ° C. The above sheet (including printing) and injection molding material are integrated. The obtained sheet insert molded product (Examples 5 and 6 and Comparative Example 3) was obtained (see FIG. 4 showing the sheet insert molded product 50 of Example 5). The sheet insert molded product 50 includes a resin layer 52 formed of PMMA resin which is an injection molding material.

  The screen portion of the hard coat surface (flat surface) for the pneumatic molded products (shaped products) of Examples 1 to 4 and Comparative Examples 1 and 2 manufactured in this way, and the sheet insert molded products of Examples 5 and 6 and Comparative Example 3 Part) was evaluated by the above method. The results are shown in Table 1.

表１より明らかであるように、熱線遮断層、熱線反射層を設けて賦形した実施例のシート（賦形品）１０、２０、および４０等、およびシートインサート成形品５０においては、加熱される温度が、画面部位だけ周辺部よりも低いために表面が荒れる事がなく、歪み発生も抑えられた。このため、実施例においては、外観がいずれも良好であるとともに、表面粗さＲａの値が、シート（実施例１〜４）において０．０２μｍ以下、シートインサート成形品（実施例５および６）においても０．０６μｍ以下に抑制された。また4mmの立ち上がり部位に関しては、加熱抑制されていない所定温度で加熱されたために、賦形性も高くできていた。

As is clear from Table 1, in the sheet (shaped product) 10, 20, and 40 of the example formed by providing the heat ray blocking layer and the heat ray reflective layer, the sheet insert molded product 50 is heated. The surface temperature is lower than the peripheral part only at the screen part, so the surface is not roughened and the occurrence of distortion is suppressed. For this reason, in an Example, while all external appearance is favorable, the value of surface roughness Ra is 0.02 micrometer or less in a sheet | seat (Examples 1-4), a sheet insert molded product (Examples 5 and 6). Was also suppressed to 0.06 μm or less. In addition, the 4 mm rising portion was heated at a predetermined temperature that was not suppressed, so that the formability was high.

  On the other hand, in the comparative sheet and sheet insert molded product without the heat ray blocking layer and the heat ray reflective layer, the PMMA layer softens and undulates because the screen part (flat part) is also heated to the same temperature as the surrounding area. Occurred. As a result, large waviness and fine uneven pattern distortion occurred on the PMMA surface or HC surface, and even after the HC film was formed, it did not disappear. That is, the surface roughness of the sheet was 0.6 μm or more, and a large value of 0.8 μm was measured for the molded product. In each comparative example, the heating temperature was not suppressed and reached the predetermined temperature in the entire region, so that the shaping was sufficient.

  In addition, in the sheet | seat of Example 2 and 4 which provided the transition area | region 37 (refer FIG. 3) as mentioned above, RS sheet | seat 10 of Example 1 in which the transition area | region is not provided in the heat ray blocking layers 16 and 26, In addition, excellent surface smoothness equivalent to that of the E-HC sheet 20 of Example 3 (see FIGS. 1 and 2) was realized, and further effects were obtained. That is, in the sheets of Examples 2 and 4, since the degree of heating suppression is changed little by little in the heat ray reflective layer 36, a boundary that can be visually recognized between the area where heating is suppressed and the area where suppression is not suppressed. The generation of lines was reliably prevented and the surface appearance was particularly good.

  The present invention should not be construed as limited to the above-described embodiments, and the embodiments may be combined. For example, the heat ray shielding layer and the heat ray reflective layer may be formed on a single sheet. Moreover, you may change suitably the shapes, such as the material of each member in each Example, and thickness.

10 RS sheet 16 of Example 1 Heat ray blocking layer (heating suppression region)
20 E-HC sheet 26 of Example 3 Heat ray blocking layer (heating suppression region)
36 Heat ray reflective layer (heating suppression area)
37 Transition region 50 Sheet insert molded product (Example 5)

Claims (14)

In a method for manufacturing a shaped article in which a film or a sheet is pneumatically heated by infrared heating, the shaped article includes a flat portion, and heating is suppressed in a plane region of the film or sheet corresponding to the flat portion. Providing a region, in the heating suppression region, suppress the heating than the peripheral region of the heating suppression region,
The method of manufacturing a shaped product, wherein the thickness of the film or sheet is 0.1 mm to 1.0 mm (excluding those having regions with different thicknesses in the flat portion of the shaped product) )   The manufacturing method of the shaped article of Claim 1 whose said heat suppression area | region is an infrared reflective layer and / or an infrared shielding heat insulation layer.   The manufacturing method of the shaped article of Claim 1 which provides the transition area | region which changed the degree of the heating suppression stepwise or continuously in the said heating suppression area | region.   The manufacturing method of the shaped article of Claim 1, 2, or 3 with which the said heat suppression area | region is formed on the transparent protective film temporarily adhered to the said film or sheet | seat.   The manufacturing method of the shaped article of Claim 1 whose local maximum elongation of this film or sheet | seat accompanying heat forming is 30% or more.   2. The stress according to claim 1, wherein in the scratch resistance test of the hard coat surface of the film or sheet (according to ASTM D 2486-79, using a pig hair brush and 200 reciprocations at a load of 450 g), 10 scratches or less are generated. A method for manufacturing shaped products. Film or sheet is heated by infrared to produce a molded product by pneumatic molding, and the molded product is directly or punched and attached to a mold, and a thermoplastic resin is injection-integrated on the back of the molded product In the method of manufacturing an insert molded product, the molded product includes a flat portion, and a heating suppression region is provided in the planar region of the film or sheet corresponding to the flat portion, and the heating suppression is performed in the heating suppression region. Suppresses heating more than the surrounding area,
A method for producing a sheet insert molded article, wherein the film or sheet has a thickness of 0.1 mm to 1.0 mm (however, there are areas having different thicknesses in the flat portion of the sheet insert molded article) Except) .   The method for producing a shaped product or a sheet insert molded product according to claim 1 or 7, wherein the film or sheet is heated by infrared rays and is compressed by air with pressurized air.   The manufacturing method of the shaped article or sheet insert molded article of Claim 1 or 7 with which the design is given to the back surface on the opposite side to a hard-coat surface in the said film or sheet | seat.   The manufacturing method of the shaped article or sheet insert molded article according to claim 1 or 7, wherein the hard coat surface of the film or sheet is heated as an outer surface.   The shaped product or sheet insert molding according to claim 1 or 7, wherein the film or sheet is a co-extruded product of an aromatic polycarbonate resin and an acrylic resin, and the hard coat surface is formed on the acrylic resin layer. Product manufacturing method.   The shaped article or sheet insert molded article according to claim 1 or 7, wherein the film or sheet has a hard coat surface, and the shaped article or the molded article includes a flat portion in a hard coat layer. Production method.   The manufacturing method of the sheet insert molded article of Claim 7 which provides the transition area | region which changed the degree of the heating suppression stepwise or continuously in the said heating suppression area | region.   The method for producing a shaped product or a sheet insert molded product according to claim 1 or 7, wherein the planar portion has a surface roughness Ra of 0.2 µm or less.

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