JP6917016B2 - Decorative sheets for three-dimensional molding, decorative resin molded products and their manufacturing methods - Google Patents

Description

The present invention relates to a decorative sheet for three-dimensional molding, a decorative resin molded product, and a method for producing the same.

Decorative resin molded products that are decorated by laminating a decorative sheet on the surface of the molded resin are used in various applications such as vehicle interior parts. As a molding method for such a decorative resin molded product, a decorative sheet that has been previously molded into a three-dimensional (three-dimensional) shape (offline premolding) by a vacuum molding die, a pneumatic molding die, or the like is inserted into an injection molding die and melted. An insert molding method in which a resin is injected into a mold to integrate the molded decorative sheet and the resin (see, for example, Patent Document 1), a decorative sheet is inserted into an injection molding mold, and the decorative sheet is added in the mold. Injection molding simultaneous decoration method in which a decorative sheet is molded (online premolding), molten resin is injected into a mold, and the molded decorative sheet and resin are integrated (see, for example, Patent Documents 2 and 3). Etc. are known.

In the insert molding method, in the process of preforming the decorative sheet with a vacuum forming mold, the decorative sheet is brought into close contact with the inner peripheral surface of the mold, and the decorative sheet is stretched by a vacuum action or a compressed air action.
Further, in the injection molding simultaneous decoration method, in addition to stretching the decoration sheet in the process of premolding in the injection molding mold, pressure or shear stress is applied to the decoration sheet when the molten resin is injected. Therefore, the decorative sheet is required to have three-dimensional moldability (particularly, mold extensibility). In addition, in order to improve the chemical resistance of the surface of the decorative resin molded product, the decorative sheet is required to have chemical resistance.

As the decorative sheet, a decorative sheet having a surface protective layer as the outermost layer is known (see, for example, Patent Documents 4 to 7).

Patent Document 4 describes a cured product of an ionizing radiation curable resin composition containing a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less converted to standard polystyrene and a polyfunctional (meth) acrylate monomer. A decorative sheet having a surface protective layer made of is described.

Patent Document 5 describes a decorative sheet having a surface protective layer made of a cured product of an ionizing radiation curable resin composition containing a polycarbonate (meth) acrylate and a monofunctional (meth) acrylate.

Patent Document 6 describes a decorative sheet having a surface protective layer made of a cured product of a curable resin composition containing a polyol and a polyisocyanate.

Patent Document 7 describes a decorative sheet having a surface protective layer made of a cured product of a resin composition containing blocked isocyanate.

Japanese Unexamined Patent Publication No. 2004-322501 Special Publication No. 50-19132 Special Publication No. 61-17255 Japanese Unexamined Patent Publication No. 2012-91497 Japanese Unexamined Patent Publication No. 2012-218277 Japanese Unexamined Patent Publication No. 2012-97248 Japanese Unexamined Patent Publication No. 2015-193211

However, since the surface protective layer of the decorative sheet described in Patent Document 4 has a three-dimensional crosslink formed by a polyfunctional (meth) acrylate monomer, the molding extensibility of the decorative sheet is reduced. Further, the surface protective layer of the decorative sheet described in Patent Document 5 is inferior in chemical resistance as compared with the surface protective layer containing a thermoplastic resin having a high molecular weight and a high glass transition temperature. Further, since the surface protective layer of the decorative sheet described in Patent Documents 6 and 7 has a three-dimensional urethane bond, the molding extensibility of the decorative sheet is reduced. Since the surface protective layer of the decorative sheet described in Patent Documents 6 and 7 is formed by using a two-component curable resin composition, it is not suitable for continuous production of the sheet in Roll To Roll.

Therefore, an object of the present invention is to provide a decorative sheet having excellent three-dimensional moldability and chemical resistance, a decorative resin molded product provided with the decorative sheet, and a method for producing the same.

In order to solve the above problems, the present invention provides the following inventions.
[1] A decorative sheet for three-dimensional molding including a base material sheet and a surface protective layer provided on the base material sheet.
The surface protective layer contains a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene, and (meth) acryloylmorpholine. It is formed of a cured product of an ionizing radiation curable resin composition,
The cured product of the ionizing radiation curable resin composition contains a (meth) acrylic resin containing the (meth) acryloyl morpholine as a constituent unit.
The content of the (meth) acryloyl morpholine in the (meth) acrylic resin containing the (meth) acryloyl morpholine as a constituent unit is 50% by mass with respect to the entire (meth) acrylic resin containing the (meth) acryloyl morpholine as a constituent unit. % Or more,
The decorative sheet.
[2] The decorative sheet according to [1], wherein the mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition to the (meth) acryloyl morpholine is 40:60 to 90:10. ..
[3] The decorative sheet according to [1] or [2], wherein the thermoplastic resin is a (meth) acrylic resin containing a (meth) acrylic acid ester as a constituent unit.
[4] A decorative resin molded product comprising the decorative sheet according to any one of [1] to [3] and a resin molded body integrated with the decorative sheet.
[5] The method for manufacturing a decorative sheet according to any one of [1] to [3].
The process of preparing the base sheet,
A thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene directly or via an intermediate layer on the base material sheet. A step of forming an ionizing radiation curable resin composition layer containing (meth) acryloyl morpholine, and irradiating the ionizing radiation curable resin composition layer with ionizing radiation to cure the ionizing radiation curable resin composition layer. A method of manufacturing a decorative sheet, which includes a step of making a decorative sheet.
[6] The decoration according to [5], wherein the mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition layer to the (meth) acryloyl morpholine is 40:60 to 90:10. Sheet manufacturing method.
[7] The method for producing a decorative sheet according to [5] or [6], wherein the thermoplastic resin is a (meth) acrylic resin containing a (meth) acrylic acid ester as a constituent unit.
[8] The method for manufacturing a decorative resin molded product according to [4].
The step of heating and softening the decorative sheet according to any one of [1] to [3].
A step of preforming by vacuum-sucking the softened decorative sheet and bringing it into close contact with the molding surface of the injection molding mold, and a resin in a fluid state in a cavity formed by molding the injection molding mold. A method for producing a decorative resin molded product, which comprises a step of injecting the resin into the base sheet side of the decorative sheet.
[9] The method for manufacturing a decorative resin molded product according to [4].
A step of heating and softening the decorative sheet according to any one of [1] to [3] and then vacuum-molding the decorative sheet into a three-dimensional shape using a vacuum molding mold to form a molded body of the decorative sheet. The molded product is inserted into an injection molding mold, and a fluid resin is injected into a cavity formed by molding the injection molding mold to integrate the resin on the base sheet side of the molded product. A method for manufacturing a decorative resin molded product, including a step.
[10] The method for manufacturing a decorative resin molded product according to [4].
A closed space in which the decorative sheet and resin molded body according to any one of [1] to [3] are arranged, and the closed space is divided into an upper space and a lower space with the decorative sheet as a boundary. A step of forming the closed space in which the base sheet side of the decorative sheet is located on the lower space side and the resin molded body is located in the lower space.
The step of creating a vacuum state in the upper space and the lower space,
The process of heating and softening the decorative sheet,
The step of raising the resin molded body and pressing it against the surface of the decorative sheet on the base sheet side, and the pressure difference between the upper space and the lower space in the upper space in an atmospheric pressure state or a pressurized state. A method for producing a decorative resin molded product, which comprises a step of bringing the resin molded body into close contact with the decorative sheet.

According to the present invention, a decorative sheet having excellent three-dimensional moldability and chemical resistance, a decorative resin molded product provided with the decorative sheet, and a method for producing the same are provided.

FIG. 1 is a cross-sectional view schematically showing the configuration of a decorative sheet for three-dimensional molding according to an embodiment of the present invention. FIG. 2 is a cross-sectional view schematically showing the configuration of a decorative resin molded product according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

<Decorative sheet for 3D molding>
As shown in FIG. 1, the three-dimensional molding decorative sheet 1 according to the embodiment of the present invention includes a base sheet 2 and a surface protective layer 3 provided on the base sheet 2.

"For three-dimensional molding" includes, in addition to the use of manufacturing a three-dimensional molded body (molded body having a three-dimensional shape) of a decorative sheet, a two-dimensional molded body (molded body having a sheet shape) of a decorative sheet. Applications for manufacturing are also included.

<Base sheet>
As shown in FIG. 1, the base material sheet 2 has a first main surface S1 and a second main surface S2 located on the opposite side of the first main surface S1 and is provided on the first main surface S1. Support the layer.

As the base sheet 2, a resin sheet made of a thermoplastic resin is usually used from the viewpoint of suitability for vacuum forming and compressed air forming. The resin sheet may be a single-layer sheet or a multi-layer sheet. When the resin sheet is a multi-layer sheet, the multi-layer sheets constituting the resin sheet may be made of the same resin or different resins. Examples of the thermoplastic resin constituting the resin sheet include acrylonitrile-butadiene-styrene resin (ABS resin), acrylic resin, polyester resin, polyolefin resin, polycarbonate resin, vinyl chloride resin and the like. One type of thermoplastic resin may be used alone, or two or more types may be used in combination.

Examples of the acrylic resin include methyl poly (meth) acrylate, ethyl poly (meth) acrylate, propyl poly (meth) acrylate, butyl poly (meth) acrylate, and methyl (meth) acrylate- (meth) acrylic. (Meta) such as butyl acid butyl copolymer, ethyl (meth) acrylate- (meth) butyl acrylate copolymer, ethylene- (meth) methyl acrylate copolymer, styrene-methyl acrylate copolymer (meth) ) Acrylic resin containing a single or copolymer containing an acrylic acid ester can be mentioned. In addition, "(meth) acrylic acid" means acrylic acid or methacrylic acid.

As the polyester resin, for example, an aromatic dicarboxylic acid (acid component) such as terephthalic acid, isophthalic acid, or naphthalenedicarboxylic acid and an aliphatic diol (alcohol component) such as ethylene glycol, diethylene glycol, butanediol, and hexanediol are esterified. Examples of the copolymer obtained by bonding, specifically, polyethylene terephthalate, polybutylene terephthalate, ethylene-terephthalate-isophthalate copolymer and the like can be mentioned.

Examples of the polyolefin-based resin include polyethylene, polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer and the like.

The base sheet 2 may contain a colorant. The base sheet 2 can be colored transparent, colored opaque, or the like with a colorant. Colorants include, for example, carbon black, iron black, titanium white, antimony white, chrome yellow, titanium yellow, petals, cadmium red, ultramarine, cobalt blue and other inorganic pigments; quinacridone red, isoindolinone yellow. , Organic pigments or dyes composed of particles such as phthalocyanine blue; metal pigments composed of scaly foil pieces such as aluminum and brass; pearl luster (pearl) pigments composed of scaly foil pieces such as titanium dioxide-coated mica and basic lead carbonate. And so on. As the colorant, one type may be used alone, or two or more types may be used in combination.

The base sheet 2 may contain additives such as a filler, a matting agent, a foaming agent, a flame retardant, a lubricant, an antistatic agent, an antioxidant, an ultraviolet absorber, and a light stabilizer.

The thickness of the base sheet 2 can be appropriately adjusted according to the use of the decorative sheet 1, but it is usually about 0.05 to 1.0 mm, and is preferably 0.05 to 1.0 mm from the viewpoint of manufacturing cost and the like. It is about 0.7 mm.

One or both of the first main surface S1 and the second main surface S2 of the base sheet 2 are subjected to an oxidation method and unevenness in order to improve adhesion to a layer or member provided in contact with the base sheet 2. Physical or chemical surface treatment such as law may be applied. Examples of the surface treatment by the oxidation method include corona discharge treatment, plasma treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone / ultraviolet treatment, and the like, and examples of the surface treatment by the unevenness method include the sandblast method and the like. Examples include a solvent treatment method. These surface treatments are appropriately selected according to the type of the base sheet 2, but the corona discharge treatment method is generally preferably used from the viewpoint of effectiveness and operability.

<Surface protective layer>
The surface protective layer 3 imparts surface characteristics such as chemical resistance, scratch resistance, and abrasion resistance to the decorative sheet 1 and protects the surface of the decorative sheet 1. As shown in FIG. 1, the surface protective layer 3 is located on the outermost side of the decorative sheet 1. “Chemical resistance” also includes solvent resistance properties.

As shown in FIG. 1, the surface protective layer 3 is provided on the base material sheet 2. In "provided on the base sheet 2", in addition to the case where the surface protective layer 3 is directly provided on the first main surface S1 of the base sheet 2, the surface protective layer 3 is provided on the base sheet 2. The case where the first main surface S1 is provided via the intermediate layer 4 is also included. In the present embodiment, the surface protective layer 3 is provided on the first main surface S1 of the base sheet 2 via the intermediate layer 4.

The thickness of the surface protective layer 3 is not particularly limited, but is usually about 1 to 1000 μm, preferably 1 to 50 μm, more preferably 1 to 50 μm, from the viewpoint of achieving both excellent three-dimensional moldability and chemical resistance. Is 1 to 30 μm.

The surface protective layer 3 contains a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene, and (meth) acryloylmorpholine. It is formed of a cured product of an ionizing radiation curable resin composition.

<Ionizing radiation curable resin composition>
The ionizing radiation curable resin composition comprises a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene, and (meth) acryloyl morpholine. Contains. The glass transition temperature (Tg) can be determined by a measurement method based on JIS K7121 using, for example, a differential calorimetry analyzer (DSC, manufactured by Shimadzu Corporation, model number: DSC-60).

The ionizing radiation curable resin composition is a composition containing an ionizing radiation curable resin. In the present embodiment, the ionizing radiation curable resin composition contains at least (meth) acryloyl morpholine as the ionizing radiation curable resin. The ionizing radiation curable resin is a resin that cures by undergoing a polymerization reaction by irradiation with ionizing radiation and changing to a polymer structure. Ionizing radiation is an electromagnetic wave or a charged particle beam that has an energy quantum that can polymerize or crosslink molecules. As the ionizing radiation, ultraviolet rays (UV) or electron beams (EB) are usually used, but in addition, electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion rays can also be used. ..

<(Meta) Acryloyl Morpholine>
(Meta) acryloyl morpholine is a monofunctional (meth) acrylate monomer. In addition, "(meth) acryloyl morpholine" means acryloyl morpholine or methacryloyl morpholine. Monofunctional means having one ethylenically unsaturated bond ((meth) acryloyl group) in the molecule. By irradiating an ionizing radiation curable resin composition containing (meth) acryloyl morpholin with ionizing radiation, (meth) acryloyl morpholins are polymerized with each other, and a (meth) acrylic resin containing (meth) acryloyl morpholin as a constituent unit. Is formed. When (meth) acryloylmorpholine, which is a monofunctional (meth) acrylate monomer, is used, three-dimensional cross-linking in the cured product of the ionizing radiation curable resin composition is compared with the case where polyfunctional (meth) acrylate monomer is used. It is possible to suppress the formation of the decorative sheet 1, whereby the deterioration of the three-dimensional formability (particularly, the mold extensibility) of the decorative sheet 1 due to the three-dimensional cross-linking can be suppressed. Further, since (meth) acryloyl morpholine has a high glass transition temperature (145 ° C.) when polymerized and polymerized, it has excellent three-dimensional moldability and chemical resistance not only at room temperature but also at high temperature. It can be applied to the surface protective layer 3. In addition, "(meth) acrylate monomer" means acrylate monomer or methacrylate monomer, and "(meth) acryloyl morpholine" means acryloyl morpholine or methacryloyl morpholine.

The content of (meth) acryloylmorpholine contained in the ionizing radiation curable resin composition is preferably 50% by mass or more with respect to the entire ionizing radiation curable resin contained in the ionizing radiation curable resin composition. It is more preferably 70% by mass or more, further preferably 90% by mass or more, and particularly preferably substantially 100% by mass.

<Thermoplastic resin>
The thermoplastic resin contained in the ionizing radiation curable resin composition is not particularly limited as long as the weight average molecular weight converted with standard polystyrene is 100,000 or more and 250,000 or less, and is known as thermoplastic. Resin can be used. Here, the weight average molecular weight of the thermoplastic resin is a value measured by a gel permeation chromatography (GPC) method, and is a value measured under the condition that polystyrene is used as a standard sample.

The weight average molecular weight of the thermoplastic resin can be appropriately adjusted in the range of 100,000 or more and 250,000 or less, preferably 100,000 or more and 200,000 or less, and more preferably 100,000 or more and 170,000 or less. be. When the weight average molecular weight of the thermoplastic resin is within the above range, excellent three-dimensional moldability and chemical resistance can be imparted to the decorative sheet 1.

Examples of the thermoplastic resin include (meth) acrylic resin, polyvinyl acetal (butyral resin) such as polyvinyl butyral, polyester resin such as polyethylene terephthalate and polybutylene terephthalate, vinyl chloride resin, urethane resin, polyolefin such as polyethylene and polypropylene, and the like. Styrene resin such as polystyrene and α-methylstyrene, acetal resin such as polyamide, polycarbonate and polyoxymethylene, fluororesin such as ethylene-4ethylene fluoride copolymer, polyimide, polylactic acid, polyvinyl acetal resin, liquid crystal polyester resin And so on. One of these thermoplastic resins may be used alone, or two or more thereof may be used in combination. When two or more kinds are used in combination, they may be used as a copolymer of the monomers constituting these thermoplastic resins, or each thermoplastic resin may be mixed and used. In addition, "(meth) acrylic resin" means an acrylic resin or a methacrylic resin.

Among the above thermoplastic resins, a (meth) acrylic resin is preferable, and a (meth) acrylic resin containing at least a (meth) acrylic acid ester monomer as a constituent unit is more preferable. Specifically, a homopolymer of a (meth) acrylic acid ester monomer, a copolymer of two or more different (meth) acrylic acid ester monomers, or a common weight of a (meth) acrylic acid ester monomer and another monomer. Coalescence is preferred. The "(meth) acrylic acid ester monomer" means an acrylic acid ester monomer or a methacrylic acid monomer.

Examples of the (meth) acrylic acid ester monomer include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, cyclohexyl (meth) acrylate, normal butyl (meth) acrylate, and (meth). ) Isobutyl acrylate, secondary butyl (meth) acrylate, tertiary butyl (meth) acrylate, isobonyl (meth) acrylate, 2-methyl-2-adamantyl (meth) acrylate, 2-ethyl-2-adamantyl (meth) ) Acrylate and the like are preferable examples, and methyl (meth) acrylate is more preferable. Examples of copolymers of two or more different (meth) acrylic acid ester monomers include copolymers of two or more (meth) acrylic acid esters selected from these (meth) acrylic acid ester monomers. , These copolymers may be random copolymers or block copolymers.

The other monomer that forms a copolymer with the (meth) acrylic anhydride monomer is not particularly limited as long as it can be copolymerized with the (meth) acrylic anhydride, and for example, (meth) acrylic acid. , Styrene, (maleic anhydride) maleic anhydride, fumaric acid, divinylbenzene, vinyl biphenyl, vinyl naphthalene, diphenylethylene, vinyl acetate, vinyl chloride, vinyl fluoride, vinyl alcohol, (meth) acrylonitrile, (meth) acrylamide, butadiene, isoprene , Isobutene, 1-butene, 2-butene, N-vinyl-2-pyrrolidone, dicyclopentadiene, etylidene norbornene, alicyclic olefin monomers such as norbornenes, vinyl caprolactam, citraconic anhydride, N-phenylmaleimide and the like. Maleimides, vinyl ethers and the like are preferred examples, and styrene and (maleic anhydride) are more preferable. That is, a binary copolymer of (meth) acrylic acid ester and styrene or (maleic anhydride) is preferable, and a ternary copolymer of (meth) acrylic acid ester and styrene and (maleic anhydride) maleic anhydride is preferable. The copolymer of the (meth) acrylic acid ester monomer and another monomer may be a random copolymer or a block copolymer.

The thermoplastic resin contained in the ionizing radiation curable resin composition may be dissolved or dispersed in a solvent, if necessary, and diluted to a viscosity that can be applied to the base sheet 2. Examples of the solvent or dispersion medium used for dissolving or dispersing the thermoplastic resin include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, and acetate. Ester-based organic solvents such as -2-methoxyethyl and -2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol and propylene glycol; acetone and methyl ethyl ketone , Methylisobutylketone, cyclohexanone and other ketone-based organic solvents; diethyl ether, dioxane, tetrahydrofuran and other ether-based organic solvents; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene and other chlorine-based organic solvents; and water and other inorganic solvents. Be done. As the solvent or dispersion medium, one type may be used alone, or two or more types may be used in combination. Of these, it is preferable to use methyl ethyl ketone.

When the thermoplastic resin contained in the ionizing radiation curable resin composition contains a (meth) acrylic resin, the content of the (meth) acrylic resin is preferably 30% by mass or more with respect to the entire thermoplastic resin. , More preferably 50% by mass or more, and even more preferably 70% by mass or more.

<Mass ratio of thermoplastic resin and (meth) acryloyl morpholine>
The mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition to (meth) acryloyl morpholine (the content of the thermoplastic resin: the content of (meth) acryloyl morpholine) is not particularly limited. However, it is preferably 40:60 to 90:10, more preferably 50:50 to 80:20, and even more preferably 70:30. When the mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition to (meth) acryloylmorpholine is within the above range, the decorative sheet 1 is provided with excellent three-dimensional moldability and chemical resistance. Can be done.

<Other resin components>
The ionizing radiation curable resin composition may contain other components in addition to the thermoplastic resin and (meth) acryloyl morpholine as long as the object of the present invention is not impaired. Other components include, for example, ionizing radiation curable resins other than (meth) acryloyl morpholine. As an ionizing thermosetting resin other than (meth) acryloylmorpholine, one or more of resins such as monomers, oligomers, and prepolymers having a polymerizable unsaturated bond, an epoxy group, etc. in the molecule that can be crosslinked by irradiation with ionizing radiation. Can be used. Examples of the ionizing radiation curable resin include monofunctional (meth) acrylate, polyfunctional (meth) acrylate, silicon resin such as siloxane, polyester, epoxy and the like. Of these, the formation of three-dimensional crosslinks in the cured product of the ionizing radiation curable resin composition is suppressed, thereby suppressing the three-dimensional formability (particularly, mold extensibility) of the decorative sheet 1 due to the three-dimensional crosslinks. It is preferable to use a monofunctional (meth) acrylate from the viewpoint of suppressing the decrease in the amount of the resin and from the viewpoint of reducing the viscosity of the ionizing radiation curable resin composition.

Examples of the monofunctional (meth) acrylate include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, pentyl (meth) acrylate, hexyl (meth) acrylate, and cyclohexyl (meth) acrylate. ) Acrylate, 2-ethylhexyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, isobornyl (meth) acrylate and other monomers, oligomers, prepolymers and the like can be mentioned. One type of monofunctional (meth) acrylate may be used alone, or two or more types may be used in combination.

The monofunctional (meth) acrylate can be used in the form of a monomer, an oligomer, a prepolymer, or the like, but is preferably used in the form of an oligomer from the viewpoint of improving three-dimensional moldability. Examples of the monofunctional (meth) acrylate oligomer include urethane (meth) acrylate oligomer, epoxy (meth) acrylate oligomer, polyester (meth) acrylate oligomer, polyether (meth) acrylate oligomer, polybutadiene (meth) acrylate oligomer, and silicone (meth). Examples thereof include meta) acrylate oligomers and aminoplast (meth) acrylate oligomers.

The ionizing radiation curable resin composition includes a weather resistance improving agent, an abrasion resistance improving agent, a polymerization inhibitor, a cross-linking agent, an infrared absorber, an antistatic agent, an adhesive improving agent, a leveling agent, a thixo-imparting agent, and a cup. By adding various additives commonly used in resin compositions such as ring agents, plasticizers, defoamers, fillers, solvents, and colorants, the surface protective layer has various functions, such as high hardness and scratch resistance. It is also possible to provide a so-called hard coating function, an antifogging coating function, an antifouling coating function, an antiglare coating function, an antireflection coating function, an ultraviolet shielding coating function, an infrared shielding coating function, and the like.

If necessary, the ionizing radiation curable resin composition may contain a component involved in the curing reaction of the ionizing radiation curable resin, for example, a photopolymerization initiator (sensitizer). For example, when the ionizing radiation curable resin composition is cured by irradiation with ultraviolet rays, the ionizing radiation curable resin composition preferably contains a photopolymerization initiator (sensitizer). Since the ionizing radiation curable resin is sufficiently cured by irradiating it with an electron beam, when the ionizing radiation curable resin composition is cured by irradiating it with an electron beam, the ionizing radiation curable resin composition is a photopolymerization initiator ( It does not have to contain a sensitizer).

When the ionizing radiation curable resin has a radically polymerizable unsaturated group, the photopolymerization initiator includes, for example, acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ether, Michler benzoyl benzoate, Michler ketone, diphenyl sulfide, etc. At least one of dibenzyldisulfide, diethyl oxide, triphenylbiimidazole, isopropyl-N, N-dimethylaminobenzoate and the like can be used. When the ionizing radiation curable resin composition has a cationically polymerizable functional group, the photopolymerization initiator may be, for example, an aromatic diazonium salt, an aromatic sulfonium salt, a metallocene compound, a benzoin sulfonic acid ester, or a freeleoxysulfone. At least one kind such as xonium diallyl iodosyl salt can be used.

The amount of the photopolymerization initiator added is not particularly limited, but is usually about 0.1 to 10 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin.

<Cured product of ionizing radiation curable resin composition>
The cured product of the ionizing radiation curable resin composition contains a (meth) acrylic resin containing (meth) acryloyl morpholine as a constituent unit. "A (meth) acrylic resin containing (meth) acryloyl morpholine as a constituent unit" means that all or some of the monomers constituting the (meth) acrylic resin are (meth) acryloyl morpholine. In a (meth) acrylic resin containing (meth) acryloyl morpholine as a constituent unit, all the monomers constituting the (meth) acrylic resin are (meth) acryloyl morpholine (that is, the content ratio of (meth) acryloyl morpholine is It is preferably 100% by mass). Thereby, excellent three-dimensional moldability and chemical resistance can be imparted to the surface protective layer 3.

The (meth) acrylic resin containing (meth) acryloyl morpholine as a constituent unit is formed by polymerizing (meth) acryloyl morpholine with each other. The (meth) acrylic resin containing (meth) acryloyl morpholine as a constituent unit is a random polymerization or block polymerization of (meth) acryloyl morpholin and one or more other monofunctional (meth) acrylate monomers, oligomers, prepolymers and the like. It may be a copolymer such as.

The content of (meth) acryloyl morpholin in the (meth) acrylic resin containing (meth) acryloyl morpholine as a constituent unit is 50% by mass or more with respect to the entire (meth) acrylic resin containing (meth) acryloyl morpholin as a constituent unit. Yes, preferably 70% by mass or more, more preferably 90% by mass or more, and particularly preferably substantially 100% by mass.

<Middle class>
As shown in FIG. 1, the decorative sheet 1 includes an intermediate layer 4 between the base sheet 2 and the surface protective layer 3. However, the intermediate layer 4 can be omitted. Therefore, the present invention also includes an embodiment in which the surface protective layer 3 is directly provided on the base sheet 2.

In the present embodiment, the intermediate layer 4 has a decorative layer 41 and a primer layer 42 in this order from the base sheet 2 side. However, the number of layers constituting the intermediate layer 4 is not particularly limited, and may be 1 or 2 or more. Further, the intermediate layer 4 is not limited to a decorative layer, a primer layer, or a combination thereof. The intermediate layer 4 may have, for example, an adhesive layer.

<Decorative layer>
The decorative layer 41 imparts decorativeness to the decorative sheet 1. As shown in FIG. 1, the decorative layer 41 is provided on the first main surface S1 of the base sheet 2. However, the decorative layer 41 may be provided on the second main surface S2, or may be provided on both the first main surface S1 and the second main surface S2.
The decorative layer 41 may be formed on the entire first main surface S1 and / or the second main surface S2 of the base sheet 2, or may be formed on the entire first main surface S1 and / or the second main surface S2 of the base sheet 2. It may be formed on a part of the surface.

Examples of the decorative layer 41 include a colored layer, a pattern layer, and a combination thereof.

The colored layer imparts a desired color to the decorative sheet 1. The colored layer is, for example, a solid layer formed on the entire first main surface S1 of the base sheet 2. The colored layer can function as a concealing layer that prevents changes and variations in the color of the base sheet 2 from affecting the color of the pattern on the decorative sheet 1. Examples of the solid layer forming method include a gravure printing method, an offset printing method, a screen printing method, a flexo printing method, an electrostatic printing method, an inkjet printing method, a roll coating method, a knife coating method, an air knife coating method, and a die coating method. , Lip coating method, comma coating method, kiss coating method, flow coating method, dip coating method and other coating methods. The color of the colored layer is usually an opaque color, but it may be a transparent color when the base color or pattern of the base sheet 2 or the like is utilized. Further, when the color or pattern of the base material such as the base material sheet 2 is utilized, it is not necessary to form the colored layer.

The pattern layer is a layer that imparts a desired pattern to the decorative sheet 1. The pattern layer is, for example, a printing layer formed on a part or the whole of the first main surface S1 of the base sheet 2 or a part or the whole of the surface of the colored layer. Examples of the printing method used for forming the pattern layer include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, and an inkjet printing method. The patterns that make up the pattern layer include, for example, the spring and autumn wood regions of the annual ring cross section, the wood grain pattern composed of conduits, leather (skin grain) patterns, and stones on the surface of stone materials such as marble, granite, and sand rock. Examples include eye patterns, grain patterns, tiled patterns, brickwork patterns, cloth patterns, geometric figures, characters, symbols, abstract patterns, etc., and patterns such as parquet, patchwork, etc., which are composites of these patterns. These patterns can be formed by multicolor printing with ordinary yellow, red, blue and black process colors, or by multicolor printing with special colors performed by preparing plates of the individual colors that make up the pattern. Can also be formed.

The ink used to form the decorative layer 41 is, for example, a mixture of a solvent or a dispersion medium and components such as a colorant and a binder resin. The ink may contain a colorant, an extender pigment, a stabilizer, a plasticizer, a catalyst, a curing agent and the like as other components. The ink may be an aqueous composition from the viewpoint of reducing VOC (volatile organic compound) of the sheet.

Colorants contained in the ink include, for example, inorganic pigments such as carbon black, iron black, titanium white, antimony white, yellow lead, titanium yellow, petal handle, cadmium red, ultramarine blue, cobalt blue; quinacridone red, isoindolinone. Organic pigments or dyes such as yellow and phthalocyanine blue; metal pigments made of scaly foil pieces such as aluminum and brass; pearl gloss pigments made of scaly foil pieces such as titanium dioxide-coated mica and basic lead carbonate. Can be mentioned. As the colorant, one type may be used alone, or two or more types may be used in combination.

Examples of the binder resin contained in the ink include urethane resin, (meth) acrylic urethane resin, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate- (meth) acrylic copolymer resin, and chlorinated polypropylene resin. , (Meta) acrylic resin, polyester resin, polyamide resin, butyral resin, polystyrene resin, nitrocellulose resin (nitrified cotton), cellulose acetate resin and the like. As the binder resin, one type may be used alone, or two or more types may be used in combination.

Examples of the solvent or dispersion medium contained in the ink include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, -2-methoxyethyl acetate, and acetate. Ester-based organic solvents such as -2-ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, etc. Ketone-based organic solvent; ether-based organic solvent such as diethyl ether, dioxane, tetrahydrofuran; chlorine-based organic solvent such as dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene; inorganic solvent such as water and the like. As the solvent or dispersion medium, one type may be used alone, or two or more types may be used in combination.

The decorative layer 41 may be formed by a method such as a hand-drawing method, a suminagashi method, a photographic method, a transfer method, a laser beam drawing method, or an electron beam drawing method. When the decorative layer 41 is a metal layer (metal thin film) such as aluminum, chromium, gold, silver, or copper, the decorative layer 41 can be formed by a method such as a vapor deposition method, a sputtering method, or an etching method.

The thickness of the decorative layer 41 can be appropriately adjusted according to the product characteristics, but the thickness at the time of ink coating is, for example, about 1 to 200 μm, and the thickness after drying is, for example, about 0.1 to 20 μm. There is a solid printing layer of about 1 to 20 μm, which is preferable.

<Primer layer>
As shown in FIG. 1, the primer layer 42 is provided between the decorative layer 41 and the surface protective layer 3, and improves the adhesion between these layers. The decorative sheet 1 may include a primer layer between the other two adjacent layers in order to improve the adhesion between the other two adjacent layers (for example, the base sheet 2 and the decorative layer 41). ..

The primer layer can be formed of resin. Examples of the resin constituting the primer layer 42 include (meth) acrylic resin, urethane resin, (meth) acrylic-urethane copolymer resin, vinyl chloride-vinyl acetate copolymer resin, polyester resin, butyral resin, and chlorinated resin. Examples thereof include polypropylene resin and chlorinated polyethylene resin. Among these resins, urethane resin, (meth) acrylic resin, and (meth) acrylic-urethane copolymer resin are preferable. These resins may be used alone or in combination of two or more.

Further, from the viewpoint of improving the adhesion between the decorative layer 41 and the surface protective layer 3, the primer composition constituting the primer layer 42 is preferably formed by using a cross-linking agent (curing agent). Examples of such a primer composition include a two-component curable resin containing a polyol as a main agent and an isocyanate as a cross-linking agent (curing agent). In particular, from the viewpoint of improving physical properties such as three-dimensional moldability of the decorative sheet 1, a polyol such as (meth) acrylic polyol, polycarbonate polyol and polyester polyol, and a cross-linking agent such as hexamethylene diisocyanate and 4,4-diphenylmethane diisocyanate. It is preferable to use in combination with and appropriately. Among these, it is more preferable to use a (meth) acrylic polyol and hexamethylene diisocyanate in combination.

Examples of the (meth) acrylic resin constituting the primer layer 42 include a homopolymer of (meth) acrylic acid ester, a copolymer of two or more different (meth) acrylic acid esters, and a (meth) acrylic acid ester. And copolymers with other monomers. Preferably, methyl poly (meth) acrylate, ethyl poly (meth) acrylate, propyl poly (meth) acrylate, butyl poly (meth) acrylate, methyl (meth) acrylate-butyl butyl (meth) acrylate are copolymerized. (Meta) acrylates such as coalesced, ethyl (meth) acrylate-butyl acrylate copolymer, ethylene- (meth) methyl acrylate copolymer, styrene-methyl acrylate copolymer (meth) A (meth) acrylic resin composed of a single material or a copolymer containing the above is used.

Examples of the urethane resin constituting the primer layer 42 include polyurethane polymerized using a polyol (polyhydric alcohol) as a main agent and an isocyanate as a cross-linking agent (curing agent). The polyol used as the main agent is an alcohol (polyhydric alcohol) having two or more hydroxyl groups in the molecule, and examples of the polyol include polyester polyol, polyethylene glycol, polypropylene glycol, (meth) acrylic polyol, and polyether. Examples thereof include polyols and polycarbonate polyols. Examples of the isocyanate used as a cross-linking agent (hardener) include polyvalent isocyanate having two or more isocyanate groups in the molecule, aromatic isocyanate such as 4,4-diphenylmethane diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, and hydrogen. Examples thereof include aliphatic (or alicyclic) isocyanates such as added tolylene diisocyanate and hydrogenated diphenylmethane diisocyanate. It is also possible to form a primer layer with a mixture of urethane resin and butyral resin.

Examples of the (meth) acrylic-urethane copolymer resin include (meth) acrylic-urethane (polyester urethane) block copolymer resin. Examples of the cross-linking agent (curing agent) include the above-mentioned various isocyanates. The (meth) acrylic-urethane (polyester urethane) block copolymer resin has a (meth) acrylic / urethane ratio (mass ratio), preferably (9/1) to (1/9), more preferably. Since it can be adjusted in the range of (8/2) to (2/8) and used for various decorative sheets, it is particularly preferable as a resin used in a primer composition.

Further, in the primer layer 42, if necessary, a weather resistance improving agent, an adhesive improving agent, a leveling agent, a thixotropic agent, a blocking inhibitor, a plasticizer, a defoaming agent, a filler, a solvent, a coloring agent, etc. Various additives may be added.

<Adhesive layer>
The decorative sheet 1 is provided with two adjacent layers in order to improve the adhesiveness of the two adjacent layers (for example, the base sheet 1 and the decorative layer 41) and the adhesion between the decorative sheet 1 and the resin molded product. An adhesive layer may be provided between the spaces or on the second main surface S2 of the decorative sheet. The adhesive constituting the adhesive layer can be appropriately selected depending on the layer and the resin molded product, and for example, a thermoplastic resin or a thermosetting resin is used. Examples of the thermoplastic resin include (meth) acrylic resin, (meth) acrylic modified polyolefin resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer, thermoplastic urethane resin, thermoplastic polyester resin, polyamide resin, and rubber resin. And the like, and examples of the thermoplastic resin include urethane resin, epoxy resin and the like. These resins may be used alone or in combination of two or more. The adhesive layer can be formed by a known layer forming method such as a coating method using an adhesive composition made of these resins or the like. The thickness of the adhesive layer is usually about 0.1 to 50 μm, and is preferably in the range of 1 to 30 μm from the viewpoint of obtaining sufficient adhesiveness.

<Manufacturing method of decorative sheet for 3D molding>
The decorative sheet 1 is, for example,
Step of forming the decorative layer 41 on the base sheet 2,
It can be produced by a method including a step of forming a primer layer 42 on the decorative layer 41 and a step of forming a surface protective layer 3 on the primer layer 42.

In the above manufacturing method, first, the decorative layer 41 is formed on the first main surface S1 of the base sheet 2. Prior to the formation of the decorative layer 31, the first main surface S1 of the base material sheet 2 may be subjected to treatments such as corona discharge treatment, plasma treatment, and ozone treatment. Further, a primer layer or an adhesive layer may be formed on the first main surface S1 of the base sheet 2 before the decorative layer 41 is formed.

In the above manufacturing method, the primer layer 42 is then formed on the decorative layer 41.

In the above production method, the surface protective layer 3 is then formed on the primer layer 42. The surface protective layer 3 is composed of a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more on the primer layer 42, and (meth). It can be formed by applying an ionizing radiation curable resin composition containing acryloyl morpholine and curing it. The uncured ionizing radiation curable resin composition layer formed by applying the ionizing radiation curable resin composition becomes a surface protective layer 3 by irradiating it with ionizing radiation such as an electron beam or ultraviolet rays to form a cured product. .. When an electron beam is used as ionizing radiation, its acceleration voltage can be appropriately adjusted according to the resin used, the thickness of the layer, etc., but for example, uncured ionizing radiation curing is performed at an acceleration voltage of about 70 to 300 kV. The sex resin composition layer can be cured. In electron beam irradiation, the higher the acceleration voltage, the higher the penetrating ability. Therefore, when a material deteriorated by the electron beam is used as the base sheet 2, the penetration depth of the electron beam and the ionizing radiation curable resin composition are used. By selecting the acceleration voltage so that the thicknesses of the layers are substantially the same, it is possible to suppress the irradiation of the base sheet 2 with extra electron beams, and the deterioration of the base sheet 2 due to the excess electron beams can be suppressed. It can be kept to a minimum. The irradiation dose is preferably an amount at which the crosslink density of the ionizing radiation curable resin is saturated, and is usually 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 50 kGy (1 to 5 Mrad). As the electron beam source, for example, various electron beam accelerators such as Cockloft Walton type, Van de Graaff type, resonance transformer type, insulated core transformer type, linear type, dynamistron type, and high frequency type can be used. .. When ultraviolet rays are used as ionizing radiation, those containing ultraviolet rays having a wavelength of 190 to 380 nm are emitted. The ultraviolet source is not particularly limited, and for example, a high-pressure mercury lamp, a low-pressure mercury lamp, a metal halide lamp, a carbon arc lamp, or the like is used.

When (meth) acryloylmorpholin is polymerized, it is sparingly soluble in an organic solvent generally used to dissolve the resin composition. Therefore, an ionizing radiation curable resin composition using (meth) acryloylmorpholin as a monomer is used. After being applied on the primer layer 42, it is polymerized (cured) by irradiating it with ionizing radiation. Further, the thermoplastic resin contained in the ionizing radiation curable resin composition having a weight average molecular weight converted into standard polystyrene of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more is at room temperature. Since it is a solid, it needs to be dissolved and diluted in a solvent before use. However, since the thermoplastic resin has low solubility in a solvent, it is necessary to dissolve and dilute it using an organic solvent having high dissolving power such as methyl ethyl ketone. On the other hand, when dissolved and diluted using only an organic solvent such as methyl ethyl ketone, there are manufacturing problems such as deterioration of the base sheet 2, moisture absorption when the organic solvent is volatilized, and residual organic solvent on the obtained decorative sheet 1. There is. Since the (meth) acryloylmorpholine monomer has a low viscosity, it plays a role of diluting the thermoplastic resin when used in combination with such a thermoplastic resin. In addition, monofunctional (meth) acrylate monomers generally have a pungent odor and are harmful to living organisms, whereas (meth) acryloyl morpholine monomers are compared to other monofunctional (meth) acrylate monomers. Since it has a high boiling point, it does not easily evaporate, and because it is almost odorless, it is possible to produce a safer and odorless decorative sheet 1.

<Decorative resin molded product>
As shown in FIG. 2, the decorative resin molded product 10 according to the embodiment of the present invention includes a decorative sheet 1 and a resin molded body 5 integrated with the decorative sheet 1. As shown in FIG. 2, the resin molded body 5 integrated with the decorative sheet 1 is located on the second main surface S2 side of the base sheet 2 of the decorative sheet 1. The decorative resin molded product 10 is formed by molding the decorative sheet 1 as needed and then integrating it with the resin molded body 5.

<Resin molded product>
The resin molded body 5 in the decorative resin molded product 10 of the present invention may be any as long as it can be integrated with the decorative sheet 1 at the time of injection molding. Examples of the material of the resin molded body 5 include a thermoplastic resin and a thermosetting resin.

Examples of the thermoplastic resin include polyolefin resins such as polyethylene and polypropylene, ABS resins, styrene resins, polycarbonate resins, acrylic resins, vinyl chloride resins and the like. One of these thermoplastic resins may be used alone, or two or more thereof may be used in combination.

Examples of the thermosetting resin include urethane resin and epoxy resin. These thermosetting resins may be used alone or in combination of two or more.

The decorative resin molded product 10 includes, for example, interior or exterior materials of vehicles such as automobiles; fittings such as window frames and door frames; interior materials of buildings such as walls, floors and ceilings; TV receivers, air conditioners and the like. Household appliances; Can be used for various purposes such as containers.

<Manufacturing method of decorative resin molded products>
The decorative resin molded product 10 can be manufactured by various injection molding methods such as an insert molding method, an injection molding simultaneous decoration method, a blow molding method, and a gas injection molding method, for example, using the decoration sheet 1. .. Among these injection molding methods, the insert molding method and the injection molding simultaneous decoration method are preferable. The decorative resin molded product 10 is also manufactured by a decoration method such as a vacuum crimping method in which the decorative sheet 1 or the molded body is attached to the three-dimensional resin molded body 5 prepared in advance. Can be done. Examples of such a vacuum crimping method include a TOM method (Three dimension Overlay Method) and the like.

As an insert molding method, for example,
After the decorative sheet 1 is heated and softened, it is vacuum-molded into a three-dimensional shape by a vacuum forming mold, and if necessary, the excess portion of the vacuum-formed decorative sheet 1 is trimmed to form the decorative sheet 1. The step of forming the molded body, and the molded body of the decorative sheet 1 is inserted into the injection molding mold, and the resin in a fluid state is injected into the cavity formed by molding the injection molding mold to form the decorative sheet 1. Examples thereof include a method including a step of integrating the resin on the base sheet 2 side of the molded product.

In an example of the insert molding method, the decorative sheet 1 is heated and softened by a hot plate, and then in the vacuum forming step, the softened decorative sheet 1 is vacuum formed into the surface shape of the molded product in advance by a vacuum forming die (offline). Pre-molding), and trimming the excess portion if necessary to obtain a molded body of the decorative sheet 1. Next, this molded body is inserted into an injection molding die (for example, an injection molding die), the injection molding die is molded, and the resin in a fluid state is added in the cavity formed by molding the injection molding die. A decorative resin molded product is formed by injecting the molded product of the decorative sheet 1 toward the base sheet 2 side, solidifying the filled resin, and integrating the decorative sheet 1 with the outer surface of the resin molded body 5. 10 can be manufactured.

In the vacuum forming step, the heating temperature at which the decorative sheet 1 is heated and softened is not particularly limited, and is appropriately adjusted according to the type of resin constituting the decorative sheet 1, the thickness of the decorative sheet 1, and the like. It can be, for example, about 120 to 200 ° C. Further, in the integration step, the temperature of the resin in the flowing state is not particularly limited, but can usually be about 180 to 320 ° C.

As an injection molding simultaneous decoration method, for example,
The process of heating and softening the decorative sheet 1,
It was formed by a step of preforming by vacuum-sucking the softened decorative sheet 1 and bringing it into close contact with the molding surface of an injection molding die (for example, an injection molding die), and by molding the injection molding die. Examples thereof include a method including a step of injecting a fluid resin into the cavity and integrating the resin on the base sheet side of the decorative sheet 1.

In an example of the injection molding simultaneous decoration method, the decoration sheet 1 is used as a female mold that also serves as a vacuum forming mold provided with injection molding suction holes, and the surface protective layer 3 side of the decoration sheet 1 faces the female mold side. The decorative sheet 1 is heated from the base sheet 2 side to be softened by a hot plate, and the softened decorative sheet 1 is vacuum-sucked from the female mold side to be brought into close contact with the female mold along the molding surface. Pre-molding (online pre-molding) is performed by this. Next, the female mold and the male mold are molded, and in the cavity formed by molding the female mold and the male mold, the resin in a fluid state is directed toward the base sheet 2 side of the preformed decorative sheet 1. The decorative resin molded product 10 can be manufactured by solidifying the filled resin and integrating the decorative sheet 1 with the outer surface of the resin molded body 5.

In the premolding step of the injection molding simultaneous decoration method, the heating temperature of the decoration sheet 1 is not particularly limited, and is appropriately adjusted according to the type of resin constituting the decoration sheet 1, the thickness of the decoration sheet 1, and the like. It can be, for example, about 70 to 130 ° C. Further, in the injection molding step, the temperature of the resin in the flowing state is not particularly limited, but can be, for example, about 180 to 320 ° C.

As a vacuum crimping method, for example,
A closed space in which the decorative sheet 1 and the resin molded body 5 are arranged. The closed space is divided into an upper space and a lower space with the decorative sheet 1 as a boundary, and the base sheet 2 side of the decorative sheet 1 is a lower space. A step of forming a closed space located on the side and the resin molded body 5 is located in the lower space, a step of putting the upper space and the lower space in a vacuum state,
The process of heating and softening the decorative sheet 1,
The process of raising the resin molded body 5 and pressing it against the surface of the decorative sheet 1 on the base sheet 2 side, and the upper space is in an atmospheric pressure state or a pressurized state, and the resin molded body is subjected to the pressure difference between the upper space and the lower space. Examples thereof include a method including a step of bringing the decorative sheet 1 into close contact with the decorative sheet 1.

In the vacuum crimping method, for example, a vacuum forming machine including a lower chamber box in which a space opening upward is formed and an upper chamber box in which a space opening downward is formed can be used. The lower chamber box is installed below the upper chamber box, and the opening of the upper chamber box and the opening of the lower chamber box face each other. When the lower part of the upper chamber box and the upper part of the lower chamber box are joined by moving downward of the upper chamber box and / or moving upward of the lower chamber box, the space in the upper chamber box and the lower side are joined. A closed space is formed by the space inside the chamber box. The closed space is inserted between the upper chamber box and the lower chamber box, and is divided into an upper space and a lower space with the decorative sheet 1 held in the closed space as a boundary. When the lower part of the upper chamber box and the upper part of the lower chamber box are separated by moving the upper chamber box upward and / or moving downward of the lower chamber box, the sealed state of the closed space is released. ..

The vacuum forming machine further includes a movable table that can be moved up and down, which is provided in the space of the lower chamber box. The resin molded body 5 is placed on this movable table.

The vacuum forming machine decorates the enclosed space so that the enclosed space formed by the space inside the upper chamber box and the space inside the lower chamber box is divided into an upper space and a lower space with the decorative sheet 1 as a boundary. A holding portion for holding the sheet 1, a heating portion for heating the decorative sheet 1 held by the holding portion, and a pressure adjusting portion for adjusting the pressure in the upper space and the lower space in the closed space are further provided. The heating unit has, for example, a heating plate such as a near-infrared heater or an infrared heater. The pressure regulator was connected to, for example, a pump connected to the upper chamber box to evacuate the upper space, atmospheric pressure or pressurization, and to the lower chamber box to evacuate the lower space. It has a pump and the like.

In an example of the vacuum crimping method using the vacuum forming machine described above, first, the resin molded body 5 is placed on a movable table. Next, the decorative sheet 1 is inserted between the upper chamber box and the lower chamber box and held by the holding portion. At this time, the decorative sheet 1 is held so that the base sheet 2 side of the decorative sheet 1 is located on the lower space side. Then, by moving the upper chamber box downward and / or moving the lower chamber box upward, the lower part of the upper chamber box and the upper part of the lower chamber box are joined, and the space in the upper chamber box and the lower side are joined. A closed space is formed by the space inside the chamber box. The enclosed space formed in this way is divided into an upper space and a lower space with the decorative sheet 1 as a boundary. Next, the upper space and the lower space are evacuated by the pressure adjusting unit, and the decorative sheet 1 is heated and softened by the heating unit. Next, by raising the movable table, the resin molded body 5 placed on the movable table is raised, and the resin molded body 5 is placed on the base sheet of the decorative sheet 1 from below the softened decorative sheet 1. Press against the surface on the 2nd side. Next, the pressure adjusting unit puts the upper space in an atmospheric pressure state or a pressurized state (that is, adjusts the pressure in the upper space to a pressure higher than that in the lower space in the vacuum state), and the pressure difference between the upper space and the lower space. The decorative resin molded product 10 is formed by bringing the resin molded body 5 and the decorative sheet 1 into close contact with each other and integrating them. At this time, the decorative sheet 1 is attached to the surface of the resin molded body 5 while being stretched. After that, the sealed state of the sealed space is released and the decorative resin molded product 10 is taken out. The extra portion of the taken-out decorative resin molded product 10 may be trimmed, if necessary.

The heating temperature of the decorative sheet 1 by the heating unit is not particularly limited and can be appropriately adjusted according to the type of resin constituting the decorative sheet 1, the thickness of the decorative sheet 1, and the like. For example, 60 to 200. It is about ℃.

Hereinafter, the present invention will be described in more detail based on Examples, but the present invention is not construed as being limited to the contents of the following Examples.

(1) Manufacture of decorative sheet for three-dimensional molding Using an ABS resin film (flexural modulus: 2000 MPa, thickness: 400 μm) as a base sheet, gravure printing using an acrylic resin composition on the surface of the film. A decorative layer was formed. Next, a composition containing an acrylic polyol and hexamethylene diisocyanate (hexamethylene diisocyanate was blended so that the NCO equivalent was equal to the OH equivalent of the acrylic polyol) was applied to the surface of the decorative layer as a primer layer by gravure coating. did. The thickness of the primer layer was 3 μm.
Next, an ionizing radiation curable resin composition containing a thermoplastic resin having the composition shown in Table 1 below and acryloylmorpholin or pentaerythritol triacrylate is applied to the surface of the primer layer, and the surface is protected by irradiating with an electron beam. A layer was formed.
The following resins were used as the thermoplastic resins A to C contained in the ionizing radiation curable resin composition.
Thermoplastic resin A: Weight average molecular weight: 120,000, glass transition temperature Tg: 105 ° C, homopolymer of methyl methacrylate Thermoplastic resin B: weight average molecular weight: 90,000, glass transition temperature Tg: 105 ° C, methyl methacrylate Thermoplastic resin C: Weight average molecular weight: 120,000, glass transition temperature Tg: 90 ° C., copolymer of methyl methacrylate and methacrylic acid The ionizing radiation curable resin composition is subjected to electron beam irradiation. It was applied by a gravure coat so that the thickness after curing was 10 μm. Further, the ionizing radiation curable resin composition was cured by irradiating an electron beam having an acceleration voltage of 165 kV and an irradiation dose of 50 kGy (5Mrad) as ionizing radiation.

(2) Evaluation of three-dimensional moldability (molding extensibility) Each of the decorative sheets manufactured in (1) is heated to 160 ° C. with an infrared heater to soften it, and then vacuum formed using a vacuum forming mold. After molding into the internal shapes of the molds A to D having the following shapes, the decorative sheet was cooled and then released to obtain a molded body of the decorative sheet. The three-dimensional formability (molding extensibility) of each decorative sheet was evaluated based on the appearance of the molded body of the obtained decorative sheet.
Shape A: Mold having a part with a maximum draw ratio of 70% Shape B: Mold having a part with a maximum draw ratio of 150% Shape C: Mold having a part with a maximum draw ratio of 200% Shape D: A part having a part with a maximum draw ratio of 300% Molds possessed In each mold, the "maximum stretching ratio" represents the percentage of increase in the area when the area of the decorative sheet before stretching is 100%. That is, for example, when the decorative sheet is stretched using a "mold having a portion having a maximum stretching ratio of 70%", the area becomes 170% at the maximum when the area of the decorative sheet before stretching is 100%. Means to stretch.

The evaluation criteria for three-dimensional moldability (molding extensibility) are as follows.
A: No cracks or whitening was observed in the surface protective layer, and the appearance was good.
B: A slight whitening was observed in the maximum stretched portion, but the appearance was not a problem in practical use.
C: Cracks and whitening were observed in the maximum stretched portion, and the appearance was problematic in practical use.
D: Cracks and whitening were observed in the maximum stretched portion and the portion other than the maximum stretched portion, and the appearance was practically problematic.
The evaluation results are shown in Table 1 below.

(3-1) Evaluation of chemical resistance (alcohol resistance) Prepare a sheet piece (50 mm × 50 mm) of the decorative sheet obtained in Examples and Comparative Examples, and use gauze soaked with a 10% ethanol aqueous solution. The surface protective layer of each sheet piece was rubbed 100 times back and forth with a load of 500 gf. The alcohol resistance of each decorative sheet was evaluated based on the appearance of the sheet pieces after rubbing.

The evaluation criteria for alcohol resistance are as follows.
A: There was no change in the state of the surface protective layer, and the appearance was good.
B: A slight whitening and a decrease in gloss were observed in the surface protective layer, but the appearance was not a problem in practical use.
The evaluation results are shown in Table 1 below.

(3-2) Evaluation of chemical resistance (sunscreen cream resistance) Prepare a sheet piece (50 mm × 50 mm) of the decorative sheet obtained in Examples and Comparative Examples, and prepare a commercially available sunscreen cosmetic (cream) 0. 5.5 g was evenly applied to the surface protective layer of each sheet piece. After each sheet piece coated with sunscreen cosmetics is left in an oven at 80 ° C. for 1 hour, the surface of each sheet piece is washed with a neutral detergent, and the appearance of the part (test surface) coated with sunscreen cosmetics. The sunscreen cream resistance of each decorative sheet was evaluated based on the above. The sunscreen cosmetic is a commercially available SPF 50 product and contains the following ingredients.
1- (4-Methoxyphenyl) -3- (4-tert-butylphenyl) -1,3-propanedione 3%
Salicylic acid 3,3,5-trimethylcyclohexylamine 10%
2-Ethylhexyl salicylate 5%
2-Ethylhexyl 2-cyano-3,3-diphenylacrylate 10%

The evaluation criteria for sunscreen cream resistance are as follows.
A: No abnormalities such as whitening, swelling, gloss deterioration, cracking, and peeling of the coating film were observed on the test surface, and the appearance was good.
B: A slight whitening of the coating film was confirmed on a part of the test surface, but the appearance was not a problem in practical use.
C: A slight whitening, swelling, and gloss deterioration of the coating film were confirmed on a part of the test surface, but there was no practical problem in appearance.
D: Abnormalities such as whitening, swelling, gloss deterioration, cracking, and peeling of the coating film were confirmed on the entire surface of the test surface, and the appearance was poor and there was a problem in practical use.
The evaluation results are shown in Table 1 below.

As shown in Table 1, it contains a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene, and (meth) acryloylmorpholine. The decorative sheet for three-dimensional molding of Examples 1 to 5 provided with a surface protective layer formed of a cured product of the ionizing and radiation-curable resin composition has a temperature of about 160 ° C. to a temperature at which it comes into contact with a mold. The three-dimensional moldability was good without cracks or cracks even under the conditions of a rapid temperature drop, a rapid stretching speed, and a high degree of stretching. Further, it was confirmed that the surfaces of the decorative sheets for three-dimensional molding of Examples 1 to 5 had excellent chemical resistance. That is, the three-dimensional moldable decorative sheet of the present invention exhibits excellent three-dimensional moldability and chemical resistance.

<Other aspects>
According to a further aspect of the invention
A decorative sheet for three-dimensional molding including a base sheet and a surface protective layer provided on the base sheet.
The surface protective layer contains a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene, and (meth) acryloylmorpholine. The decorative sheet formed of a cured product of an ionizing radiation curable resin composition is provided.
In this embodiment, it is preferable that the cured product of the ionizing radiation curable resin composition contains a (meth) acrylic resin containing the (meth) acryloyl morpholine as a constituent unit.
In the aspect of the present invention, the mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition to the (meth) acryloyl morpholine is preferably 40:60 to 90:10.
In this embodiment, it is preferable that the thermoplastic resin is a (meth) acrylic resin containing a (meth) acrylic acid ester as a constituent unit.
Further, according to still another aspect of the present invention, there is also provided a decorative resin molded product including any of the above-mentioned decorative sheets and a resin molded body integrated with the decorative sheet.
Further, according to still another aspect of the present invention.
A method for manufacturing any of the above decorative sheets.
The process of preparing the base sheet,
A thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene directly or via an intermediate layer on the base material sheet. A step of forming an ionizing radiation curable resin composition layer containing (meth) acryloyl morpholine, and irradiating the ionizing radiation curable resin composition layer with ionizing radiation to cure the ionizing radiation curable resin composition layer. Process to make
A method for manufacturing a decorative sheet including the above is also provided.
In this embodiment, the mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition layer to the (meth) acryloyl morpholine is preferably 40:60 to 90:10.
In this embodiment, it is preferable that the thermoplastic resin is a (meth) acrylic resin containing a (meth) acrylic acid ester as a constituent unit.
Further, according to still another aspect of the present invention.
The method for manufacturing the above-mentioned decorative resin molded product.
The process of heating and softening any of the above decorative sheets,
A step of preforming by vacuum-sucking the softened decorative sheet and bringing it into close contact with the molding surface of the injection molding mold, and a resin in a fluid state in a cavity formed by molding the injection molding mold. Also provided is a method for producing a decorative resin molded product, which comprises a step of injecting the resin into the base sheet side of the decorative sheet.
Further, according to still another aspect of the present invention.
The method for manufacturing the above-mentioned decorative resin molded product.
After heating and softening any of the above decorative sheets, a step of vacuum forming into a three-dimensional shape by a vacuum molding die to form a molded body of the decorative sheet, and inserting the molded body into an injection molding die. A decorative resin molded product comprising a step of injecting a fluid resin into a cavity formed by molding the injection molding mold and integrating the resin with the base sheet side of the molded product. Manufacturing methods are also provided.
Further, according to still another aspect of the present invention.
The method for manufacturing the above-mentioned decorative resin molded product.
An enclosed space in which any of the above-mentioned decorative sheets and resin molded bodies is arranged, and the enclosed space is divided into an upper space and a lower space with the above-mentioned decorative sheet as a boundary, and the above-mentioned base material sheet of the above-mentioned decorative sheet. A step of forming the closed space in which the side is located on the lower space side and the resin molded body is located in the lower space.
The process of creating a vacuum in the upper space and the lower space,
The process of heating and softening the decorative sheet,
The step of raising the resin molded body and pressing it against the surface of the decorative sheet on the base sheet side, and the pressure difference between the upper space and the lower space in the upper space in an atmospheric pressure state or a pressurized state. Also provided is a method for producing a decorative resin molded product, which comprises a step of bringing the resin molded body into close contact with the decorative sheet.

1: Decorative sheet 2: Base sheet 3: Surface protection layer 4: Intermediate layer 41: Decorative layer 42: Primer layer 5: Resin molded product S1: First main surface of base sheet S2: Second base sheet Main surface

Claims (10)

A decorative sheet for three-dimensional molding including a base sheet and a surface protective layer provided on the base sheet.
The surface protective layer contains a thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene, and (meth) acryloylmorpholine. It is formed of a cured product of an ionizing radiation curable resin composition,
The cured product of the ionizing radiation curable resin composition contains a (meth) acrylic resin containing the (meth) acryloyl morpholine as a constituent unit.
The content of the (meth) acryloyl morpholine in the (meth) acrylic resin containing the (meth) acryloyl morpholine as a constituent unit is 50% by mass with respect to the entire (meth) acrylic resin containing the (meth) acryloyl morpholine as a constituent unit. % Or more,
The decorative sheet. The decorative sheet according to claim 1, wherein the mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition to the (meth) acryloyl morpholine is 40:60 to 90:10. The decorative sheet according to claim 1 or 2, wherein the thermoplastic resin is a (meth) acrylic resin containing a (meth) acrylic acid ester as a constituent unit. A decorative resin molded product comprising the decorative sheet according to any one of claims 1 to 3 and a resin molded body integrated with the decorative sheet. The method for manufacturing a decorative sheet according to any one of claims 1 to 3.
The process of preparing the base sheet,
A thermoplastic resin having a weight average molecular weight of 100,000 or more and 250,000 or less and a glass transition temperature of 95 ° C. or more converted to standard polystyrene directly or via an intermediate layer on the base material sheet. A step of forming an ionizing radiation curable resin composition layer containing (meth) acryloyl morpholine, and irradiating the ionizing radiation curable resin composition layer with ionizing radiation to cure the ionizing radiation curable resin composition layer. A method of manufacturing a decorative sheet, which includes a step of making a decorative sheet. The production of the decorative sheet according to claim 5, wherein the mass ratio of the thermoplastic resin contained in the ionizing radiation curable resin composition layer to the (meth) acryloyl morpholine is 40:60 to 90:10. Method. The method for producing a decorative sheet according to claim 5 or 6, wherein the thermoplastic resin is a (meth) acrylic resin containing a (meth) acrylic acid ester as a constituent unit. The method for manufacturing a decorative resin molded product according to claim 4.
A step of heating and softening the decorative sheet according to any one of claims 1 to 3.
A step of preforming by vacuum-sucking the softened decorative sheet and bringing it into close contact with the molding surface of the injection molding mold, and a resin in a fluid state in a cavity formed by molding the injection molding mold. A method for producing a decorative resin molded product, which comprises a step of injecting the resin into the base sheet side of the decorative sheet. The method for manufacturing a decorative resin molded product according to claim 4.
A step of heating and softening the decorative sheet according to any one of claims 1 to 3, and then vacuum-molding the decorative sheet into a three-dimensional shape using a vacuum molding mold to form a molded body of the decorative sheet. The molded product is inserted into an injection molding mold, and a fluid resin is injected into a cavity formed by molding the injection molding mold to integrate the resin on the base sheet side of the molded product. A method for manufacturing a decorative resin molded product, including a step. The method for manufacturing a decorative resin molded product according to claim 4.
A closed space in which the decorative sheet and the resin molded body according to any one of claims 1 to 3 are arranged, and the closed space is divided into an upper space and a lower space with the decorative sheet as a boundary. A step of forming the closed space in which the base sheet side of the decorative sheet is located on the lower space side and the resin molded body is located in the lower space.
The step of creating a vacuum state in the upper space and the lower space,
The process of heating and softening the decorative sheet,
The step of raising the resin molded body and pressing it against the surface of the decorative sheet on the base sheet side, and the pressure difference between the upper space and the lower space in the upper space in an atmospheric pressure state or a pressurized state. A method for producing a decorative resin molded product, which comprises a step of bringing the resin molded body into close contact with the decorative sheet.

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