JP7405700B2 - Manufacturing method for decorative resin products - Google Patents

Description

The present invention relates to a method for manufacturing decorative resin products, and particularly to a method for advantageously manufacturing decorative resin products having a three-dimensional shape that can be suitably used as interior parts for automobiles, etc. .

BACKGROUND ART Conventionally, resin products using various sheet-like bodies have been proposed and used for the purpose of improving the physical properties of resin products, decorating them, and the like. For example, in Patent Document 1 (Japanese Unexamined Patent Application Publication No. 2005-169803), as a method for manufacturing a decorated high-rigidity molded product suitably used as an automobile body component, 1) transparent or translucent molded products made of thermoplastic resin are manufactured. A decorative sheet is formed by stacking a transparent sheet and a carbon fiber-containing fabric sheet in a two-layer or multi-layer configuration with the transparent sheet positioned at least on the front side and joining them by heat pressing. 2) A decorated highly rigid molded product having a structure in which the decorative sheet is bonded to the surface of the highly rigid molded product by inserting the decorative sheet into a molding die and molding by injection molding or the like. A method of manufacturing is disclosed.

Furthermore, in Patent Document 2 (Japanese Patent No. 5519364), a transparent resin sheet, a silylated urethane adhesive, and , discloses a wood-like decorative sheet in which wood layers are laminated in this order, and in the same patent document, the wood-like decorative sheet is housed in a cavity as an insert, and the wood-like decorative sheet is injection molded. Resin molded products have also been proposed.

Incidentally, various resin products have been used for various interior parts of automobiles, and in recent years, the demand for decorated resin products has been increasing. For example, ornaments (decorative panels) are widely used in the dash panels placed at the front of the car interior from a design perspective, but especially in luxury cars, resin products made of wood are sought after as ornaments. It is being

Here, there are various ornaments, including those clearly shown in FIG. 1 etc. in Patent Document 3 (Japanese Unexamined Patent Application Publication No. 2016-28914) (the member designated with reference numeral 5 in the drawing of the same patent document). However, in recent years, as the designs of automobile dash panels have become more diverse and complex, ornaments are required to have three-dimensional shapes that are even more complex than conventional products. It is becoming more and more common.

However, when the present inventors conducted a detailed study on conventional decorative sheets such as the decorative sheet disclosed in Patent Document 1 and the wood-like decorative sheet disclosed in Patent Document 2, it was found that When a resin product with a complicated three-dimensional shape is manufactured using a decorative sheet according to the so-called insert molding method, the decorative sheet cannot conform to the required three-dimensional shape and the resin base formed by the insert molding method It has been found that there is a risk that sufficient adhesion between the decorative sheet and the decorative sheet may not be obtained, and that problems such as displacement and cracking of the decorative sheet may occur.

Japanese Patent Application Publication No. 2005-169803 Patent No. 5519364 Japanese Patent Application Publication No. 2016-28914

The present invention has been made against this background, and the problem to be solved is to advantageously produce decorative resin products having complex three-dimensional shapes according to the insert molding method. The purpose is to provide a method for manufacturing.

In order to solve such problems, the present invention provides a transparent or translucent ultraviolet curable paint containing a thermosetting agent, a decorative sheet that can be penetrated by such an ultraviolet curable coating, and a transparent or translucent synthetic resin. A method for producing a decorative resin product using a synthetic resin film, a base film, and a synthetic resin substrate, wherein (I) on one side of the base film, i) a transparent or translucent film containing the thermosetting agent; ii) the ultraviolet rays formed by irradiating a thin film of the transparent or translucent ultraviolet curable coating containing the thermosetting agent with ultraviolet rays; a second layer composed of a semi-cured product of a curable paint and brought into close contact with the first layer by irradiation with ultraviolet rays, and iii) from the transparent or translucent synthetic resin film. (II) Next, on the other side of the base film in the laminated film, the synthetic resin base material is laminated according to the insert molding method. A semi-cured product of a transparent or semi-transparent ultraviolet curable paint containing the thermosetting agent constituting each of the first and second layers of the laminated film, which is integrally molded, and is heated by the heat during insert molding. By curing, 1) a base film layer consisting of the base film, and 2) a cured product of a transparent or translucent ultraviolet curable paint containing the thermosetting agent are formed on one surface of the synthetic resin base material. 3) an intermediate layer composed of a cured product of a transparent or translucent ultraviolet curable paint containing the thermosetting agent; and 4) a protective layer comprising the above-mentioned decorative sheet. The gist of the present invention is a method for producing a decorated resin product, which is characterized by producing a decorated resin product in which adjacent layers are laminated in close contact with each other.

Here, in a first preferred embodiment of the method for producing a decorated resin product according to the present invention, the laminated film comprises: 1) the decorative sheet is laminated on one surface of the base film; 2) Using the laminate a1, one surface of the base film is impregnated with a transparent or translucent ultraviolet curable paint containing the thermosetting agent. a step of producing a laminate a2 in which a layer consisting of the decorative sheet and a layer consisting of a coating film of a transparent or translucent ultraviolet curable paint containing the thermosetting agent are laminated in this order; ) In the laminate a2, the transparent or semi-transparent synthetic resin film is laminated on the surface of the layer consisting of the transparent or semi-transparent ultraviolet curable paint film containing the thermosetting agent, and the lamination is in such a state. It is manufactured through a step of irradiating the body a2 with ultraviolet rays.

In a second preferred embodiment of the method for producing a decorated resin product according to the present invention, the laminated film may include: 1) a transparent or translucent film containing the thermosetting agent on one surface of the base film; 2) a step of producing a laminate b1 having a layer made of the decorative sheet impregnated with an ultraviolet curable paint; and 2) a transparent or translucent layer containing the thermosetting agent that has been brought into a semi-cured state by irradiation with ultraviolet rays. 3) from the decorative sheet impregnated with the transparent or translucent UV-curable paint containing the thermosetting agent in the laminate b1; By laminating the film for the intermediate layer on the upper surface of the layer and irradiating the laminate b1 in such a state with ultraviolet rays, a laminate b2 consisting of the laminate b1 and the film for the intermediate layer is formed. and 4) laminating the transparent or translucent synthetic resin film on the surface of the intermediate layer film in the laminate b2.

Furthermore, in a third preferred embodiment of the method for manufacturing a decorated resin product according to the present invention, the decorative sheet is a wood sheet, an inorganic fiber sheet, an organic fiber sheet, or a Japanese paper sheet.

Furthermore, in a fourth preferred embodiment of the method for producing a decorated resin product according to the present invention, the ultraviolet curable paint is an unsaturated polyester resin paint.

As described above, in the method for producing a decorated resin product according to the present invention, when producing a target decorated resin product according to the insert molding method, a laminated film having a predetermined configuration, specifically, i. ) a first layer consisting of a decorative sheet containing a semi-cured product of a transparent or translucent UV-curable paint containing a thermosetting agent; ii) a transparent or translucent UV-curing paint containing a thermosetting agent; a second layer formed by a semi-cured product of the ultraviolet curable coating material formed by irradiating the thin film with ultraviolet rays, and which is brought into close contact with the first layer by the irradiation of ultraviolet rays, and iii. ) A laminated film is used in which a protective layer made of a transparent or translucent synthetic resin film is laminated on one surface of a base film in this order. In such a laminated film, the UV-curable paint contained in the decorative sheet is semi-cured, and the UV-curable paint is interposed between the first layer made of the decorative sheet and the protective layer. The second layer is also composed of semi-cured UV-curable paints, and the presence of these semi-cured materials makes it possible for the laminated film to be used to form the desired decorative resin product during insert molding. The decorative sheet can be advantageously deformed according to the external shape (the shape of the molding cavity in the mold) without breaking. Therefore, according to the manufacturing method according to the present invention, decorative resin products having complex three-dimensional shapes or shapes with curved surfaces with large curvature, etc., which are difficult to manufacture using conventional insert molding methods, can be manufactured. can also be advantageously produced.

Furthermore, in the manufacturing method according to the present invention, the UV-curable paint present in the laminated film before the insert molding method is carried out is a semi-cured product, and the paint contains a thermosetting agent. Therefore, the heat during insert molding favorably progresses the curing of the UV-curable paint present in the laminated film, and as a result, in the final decorative resin product, the base film and the UV-curable paint The adhesion with the decorative layer made of the decorative sheet containing the cured mold paint and the adhesion between each layer on the base film are excellent.

Furthermore, according to the manufacturing method of the present invention, a transparent or translucent ultraviolet curable paint containing a thermosetting agent is provided on the surface of the decorative layer made of a decorative sheet (the surface on the protective layer side of the same layer). It is possible to form an intermediate layer consisting of a cured product with an arbitrary thickness. Therefore, by increasing the thickness of the intermediate layer, it is possible to make the sense of depth of the decoration by the decorative sheet more noticeable in the finally obtained decorative resin product. In addition, as in the conventional manufacturing method, a decorative resin product having a complicated three-dimensional shape is manufactured by using a decorative sheet provided with a synthetic resin layer as a layer corresponding to the intermediate layer in the present invention and according to an insert molding method. When manufactured, such a decorative sheet may not follow a complicated three-dimensional shape, and as a result, there is a risk that sufficient adhesion between the resin base material formed by insert molding and the decorative sheet may not be obtained, and the This may cause problems such as shifting or cracking of the decorative sheet.

It is a perspective view showing an instrument panel equipped with a decorative resin product (ornament) manufactured according to the manufacturing method of the present invention. FIG. 1 is a perspective view showing a decorative resin product (ornament) manufactured according to the manufacturing method of the present invention. 3 is a partially enlarged sectional view of the decorative resin product (ornament) of FIG. 2. FIG. FIG. 2 is a schematic explanatory diagram showing an example of a manufacturing process of a laminated film to be subjected to insert molding in the present invention. It is a schematic explanatory drawing which shows another example of the manufacturing process of the laminated film provided for insert molding in this invention.

The present invention will be described in detail below with appropriate reference to the drawings. It should be understood that in FIG. 3, each layer formed on the synthetic resin base material 14 is appropriately exaggerated or dwarfed in order to facilitate understanding of the present invention. By the way.

FIG. 1 is a perspective view of an instrument panel 10 that is assembled at the front of the interior of an automobile, and an ornament 12 attached to the instrument panel 10 is a decorative resin product manufactured according to the manufacturing method according to the present invention. It is.

More specifically, as is clear from the perspective view of FIG. 2, the ornament 12 has a thin plate-like body bent in a dogleg shape (approximately at a right angle) as a whole, and one side of the horizontally long thin plate-like body is bent. At the end, the width in the vertical direction (vertical direction in FIG. 2) becomes gradually narrower, and the surface exposed when mounted on the instrument panel 10 is a curved surface. It is configured.

FIG. 3 is a partially enlarged sectional view showing such an ornament 12 in which each layer is laminated on a synthetic resin base material 14. As shown in FIG. 3, the ornament 12 includes a base film layer 16 and a cured product of a transparent or semi-transparent ultraviolet curable paint containing a thermosetting agent on a synthetic resin base material 14. A decorative layer 18 made of a decorative sheet, an intermediate layer 20 made of a cured product of a transparent or translucent ultraviolet curable paint containing a thermosetting agent, and a protective layer 22 made of a transparent or translucent synthetic resin film, The structure is formed by laminating layers according to this order. The ornament 12 having such a configuration is attached to the instrument panel 10 so that the protective layer 22 is exposed to the outside.

It goes without saying that the decorative resin products that can be manufactured according to the manufacturing method of the present invention are not limited to those that have the shape of the ornament 12 shown in FIGS. 1 to 3. be. In particular, according to the manufacturing method of the present invention, it is difficult to manufacture products with complex three-dimensional shapes or large curvatures, which are difficult to manufacture using the conventional insert molding method using a film containing a decorative sheet, for reasons described below. Even decorative resin products having a curved shape or the like can be advantageously manufactured.

Further, in the decorated resin product (12) manufactured according to the present invention, the thickness of each layer formed on the synthetic resin base material (14) may be adjusted as appropriate depending on the use of the decorated resin product (12). determined. For example, in the ornament 12 incorporated in the instrument panel 10 of an automobile as in the present embodiment, the base film layer 16 has a thickness of about 100 to 400 μm, the decorative layer 18 has a thickness of about 50 to 200 μm, and the intermediate layer has a thickness of about 100 to 400 μm. The thickness of the protective layer 20 is approximately 10 to 2000 μm, and the thickness of the protective layer 22 is approximately 30 to 200 μm.

According to the manufacturing method of the present invention, the ornament 12 shown in FIGS. 1 to 3 is manufactured by: 1) First, a decoration containing a semi-cured product of a transparent or translucent ultraviolet curable paint containing a thermosetting agent; A first layer consisting of a sheet, a second layer consisting of a semi-cured product of a transparent or translucent ultraviolet curable paint containing a thermosetting agent, and a protective layer consisting of a transparent or translucent synthetic resin film, According to this order, a laminated film is produced by laminating on one side of the base film, and then 2) a synthetic resin base is formed on the other side of the base film in the laminated film according to the insert molding method. Manufactured by integrally molding materials.

Here, the method for producing the laminated film to be subjected to insert molding is not particularly limited, but advantageously, a transparent or translucent ultraviolet curable paint containing a thermosetting agent and such an ultraviolet curable paint are used. It is possible to manufacture according to the method (manufacturing method) described in detail below using a decorative sheet that is permeable to water, a transparent or translucent synthetic resin film, and a base film. 4 and 5 each schematically shows an outline of an advantageous manufacturing method for the laminated films 30, 70 used for insert molding in the present invention. Although FIGS. 4 and 5 are not cross-sectional views, each layer constituting the film or the laminate is hatched for easy understanding.

1) Manufacturing method I of laminated film (manufacturing method of laminated film 30)
First, a laminate 36 (laminate a1) having a layer made of a decorative sheet (decorative sheet layer 34) on one surface of the base film 32 is produced (FIG. 4(a)). The laminate 36 having such a structure can be produced, for example, by attaching a decorative sheet to the base film 32 using a heat press, an adhesive, or the like.

Here, the material constituting the base film 32 is not particularly limited as long as it can be integrated with the synthetic resin base material (14) by fusion or the like by insert molding, which will be described later. For example, the synthetic resin base material 14 is made of ABS resin (acrylonitrile-butadiene-styrene copolymer resin), a composite material in which glass fiber is added to ABS resin, or an ABS-based synthetic resin material such as PC (polycarbonate)/ABS resin. In the case where the base film 32 is made of ABS, the same ABS-based synthetic resin material is advantageously selected and used as the material constituting the base film 32.

In addition, the decorative sheet used in the present invention is a sheet-like body that can be penetrated by a transparent or translucent ultraviolet-curing liquid paint containing a thermosetting agent, which will be described later, and which is suitable for the final resin product. Any material that can be decorated can be used in the present invention without particular limitation. Note that the term "transparent or translucent UV-curable paint containing a thermosetting agent permeable" means that such UV-curable paint can penetrate into the inside of the sheet. In the present invention, wood sheets, inorganic fiber sheets, organic fiber sheets, Japanese paper sheets, etc. are advantageously used.

-Wood material sheet-
As the wood material sheet used in the present invention, conventionally known natural wood veneers or artificial wood veneers can be used. Natural wood veneers that can be used in the present invention include bird's eye maple, sapele mahogany, mappa, rosewood, marble wood, Claro walnut, bubinga, teak, cedar, white ash, black walnut, zebra wood, pine, cypress, and white oak. Examples include natural wood veneers such as curly maple, eucalyptus, ebony, zelkova, and red oak. Furthermore, examples of the artificial veneer that can be used in the present invention include those sliced from a laminate of artificial veneers, and those made by inlaying wood material into metal or the like.

-Inorganic fiber sheets, organic fiber sheets, Japanese paper sheets-
In the present invention, 1) an inorganic fiber sheet made of inorganic fibers such as carbon fibers, glass fibers, and metal fibers; 2) plants such as cotton fibers, hemp fibers, silk fibers, and wool (wool, animal hair); Alternatively, organic fiber sheets made of animal-derived organic fibers or various artificially synthesized organic fibers, and (3) various Japanese paper sheets can also be used as decorative sheets. The thickness (diameter) of the inorganic fibers constituting the inorganic fiber sheet is approximately 7 μm to 10 μm, and the thickness (diameter) of the organic fibers constituting the organic fiber sheet is approximately 5 μm to 7 μm. Examples of each can be given. In addition, inorganic fiber sheets and organic fiber sheets may have any structure as long as they can be penetrated by a transparent or translucent ultraviolet curing paint containing a thermosetting agent, and may be any type of fabric such as woven fabric, knitted fabric, or non-woven fabric. It can also be used in any form.

Of course, each of the above-mentioned wood sheets and the like can be used alone, and it is also possible to use a plurality of the same type or two or more types stacked one on top of the other.

Further, examples of UV-curable paints that can be used in the present invention include unsaturated polyester resin paints and acrylic resin paints, but in the present invention, the curing level (cured state) is An unsaturated polyester resin-based ultraviolet curable paint is advantageously used because it is easy to adjust and has relatively good adhesion to decorative sheets (particularly wood sheets). Furthermore, ultraviolet curable paints (UV curable transparent paints) that yield transparent cured products and UV curable paints that yield translucent cured products are advantageously used in the present invention. In the present specification and claims, the term "transparent or translucent ultraviolet curable paint" means an ultraviolet curable paint from which a transparent or translucent cured product can be obtained.

In addition, in the present invention, in order to uniformly adjust the curing level (cured state) of the entire paint, it is advantageous to use an ultraviolet curable paint that is cured by ultraviolet light with a relatively long wavelength of about 400 nm to 450 nm. used. Specifically, an ultraviolet curable paint containing as a polymerization initiator a compound that functions as a polymerization initiator when irradiated with ultraviolet light of about 400 nm to 450 nm is advantageously used. Examples of such polymerization initiators include monoacylphosphine oxide (MAPO, product example: Lucirin TPO), bisacylphosphine oxide (BAPO, product example: Irgacure 819), and blends thereof (product example: Irgacure 1700). Examples include acylphosphine oxide-based polymerization initiators.

In addition, in the present invention, such an ultraviolet curable paint is used with the addition of a thermosetting agent for thermosetting resins, monomers, oligomers, etc. contained in the paint. By using an ultraviolet curable coating material to which such a thermosetting agent is added, the semi-cured product of the ultraviolet curable coating material can be effectively cured by heating during insert molding. In the present invention, the thermosetting agent is appropriately selected depending on the resin contained in the ultraviolet curable paint used. For example, an unsaturated polyester resin-based ultraviolet curable paint is used. In this case, peroxycarbonates and the like are advantageously used.

Next, the laminate 36 (laminate a1) is placed in a predetermined mold, and the decorative sheet layer 34 on the base film 32 of the laminate 36 (laminate a1) is coated with a transparent material containing the above-mentioned thermosetting agent. Or, the decorative sheet layer 34 is made into a layer 38 made of a decorative sheet impregnated with a transparent or translucent UV-curable paint containing a thermosetting agent by impregnating it with a translucent UV-curable paint, and then, A layer 40 consisting of a transparent or translucent ultraviolet curable paint film containing a thermosetting agent is formed on the layer 38 to produce a laminate 42 (laminate a2) (FIG. 4(b)). .

Here, when forming the layer 40 made of a transparent or translucent ultraviolet curable paint film containing a thermosetting agent, the coating layer 40 has a higher temperature than the ultraviolet curable paint impregnated into the decorative sheet layer It is preferable to use a UV-curable paint of high viscosity. The viscosity of the ultraviolet curable paint can be adjusted by increasing or decreasing the amount of solvent. Further, the UV-curable paint impregnated into the decorative sheet layer 34 and the UV-curable paint used to form the coating film (layer 40) on the decorative sheet may be different, but Preferably, paints of the same type (paints containing the same components that harden by ultraviolet irradiation) are used.

In the thus formed laminate 42 (laminate a2), a layer 40 consisting of a transparent or translucent ultraviolet curing paint film containing a thermosetting agent is coated with PET resin, PC resin, PMMA resin, etc. A transparent synthetic resin film 44 is attached according to a known method to obtain a laminate 46 (FIG. 4(c)). In addition, in the present invention, it is also possible to use a translucent synthetic resin film instead of the transparent synthetic resin film 44.

Then, by irradiating the laminate 46 with ultraviolet rays, the desired laminate film 30 is obtained (FIG. 4(d)). Specifically, i) a first layer 48 consisting of a decorative sheet containing a semi-cured product of a transparent or translucent ultraviolet curable paint containing a thermosetting agent; ii) a transparent or translucent coating containing a thermosetting agent; iii) a protective layer made of a transparent synthetic resin film 44 are laminated on one surface of the base film 32 in this order. A laminated film 30 is obtained.

Here, when manufacturing the laminated film 30 using this manufacturing method, it is preferable that the laminated body 46 placed in the mold is once exposed to a negative pressure environment and then irradiated with ultraviolet rays under a pressurized environment. By exposing the laminate 46 to a negative pressure environment, air unintentionally remaining between each layer is effectively removed, and the adhesion between each layer is improved more effectively in the final decorated resin product. In addition, uniformity of the product surface can be advantageously achieved.

In addition, the ultraviolet irradiation to the laminate 46 includes: 1) ultraviolet irradiation to the first layer 48 (layer 38 made of a decorative sheet impregnated with a transparent or translucent ultraviolet curable paint containing a thermosetting agent); 2) The ultraviolet curable paint contained in the layer formed by the above-mentioned second layer 50 (a transparent or semi-transparent ultraviolet curable paint containing a thermosetting agent) is in a semi-cured state; The layer (formed by ultraviolet irradiation) of the layer 40 consisting of a film is made of a semi-cured product of an ultraviolet curable paint. Here, the term "semi-cured UV-curable paint" refers to a paint that has been cured to some extent but still has room for curing. The laminated film 30 is heated during insert molding, which will be described later, and the ultraviolet rays contained in the first layer 48 are heated so that the heat during the insert molding acts on the thermosetting agent in the paint to complete the curing of the paint. It is necessary to keep the curable paint in a semi-cured state (a state in which there is still room for curing), and even if the UV-curable paint forming the second layer 50 is in a semi-cured state, It needs to be stopped. Therefore, various irradiation conditions such as peak illumination intensity and integrated illuminance are determined for ultraviolet irradiation in this step, taking into consideration the heating in the subsequent insert molding. In the present invention, as the ultraviolet lamp used for ultraviolet irradiation, metal halide lamps, xenon lamps, UV-LED lamps, etc., which are capable of emitting ultraviolet rays in a long wavelength range, are advantageously used.

2) Manufacturing method II of laminated film (manufacturing method of laminated film 70)
In addition, in this production method II, the base film, decorative sheet, transparent or translucent UV-curable paint containing a thermosetting agent, and transparent or translucent synthetic resin used in the above-mentioned "Laminated film production method I" are also used. Since film can be used, the explanation will be omitted. Further, in FIG. 5, components having the same configuration as those in FIG. 4 are designated by the same reference numerals as in FIG. 4, and their explanations will be omitted.

First, a laminate 54 (laminate b1) having a layer 52 made of a decorative sheet impregnated with a transparent or translucent ultraviolet curable paint containing a thermosetting agent on one surface of the base film 32 is produced. (Figure 5(a)). The laminate 54 (laminate b1) having such a configuration is, for example, a decorative sheet pasted onto the base film 32 using heat press, an adhesive, etc., and a transparent or translucent film containing a thermosetting agent. It can be produced by immersing it in an ultraviolet curable paint.

When producing the laminate 54 (laminate b1) having such a configuration, in particular, by permeating the ultraviolet curable paint into the decorative sheet under negative pressure or under pressure, the lamination into the paint is reduced. It is possible to shorten the soaking time of the body (laminated body formed by pasting the decorative sheet on the base film 32). For example, by vacuuming the laminate for 5 minutes or more under a negative pressure of -0.080 MPa or less while the laminate is immersed in the paint, the paint can advantageously penetrate into the decorative sheet. . In addition, when using a wood sheet as a decorative sheet, depending on the type of wood that makes up the wood sheet, the wood sheet may be acetylated and then dipped into paint. As a result, the penetration of the paint into the wood sheet progresses advantageously.

While producing such a laminate 54 (laminate b1), an intermediate layer film 56 made of a semi-cured ultraviolet curing paint containing a thermosetting agent is produced (FIG. 5(b)). As for the UV-curable paints used here, UV-curable paints that yield transparent cured products and UV-curable paints that yield translucent cured products (transparent or translucent UV-curable paints) are advantageous. used. Further, the ultraviolet curable paint used when producing the intermediate layer film 56 may be different from the ultraviolet curable coating used when producing the laminate 54 described above, but is preferably of the same type. Paints (paints with the same components that harden when exposed to ultraviolet rays) are used.

The intermediate layer film 56 is formed, for example, by continuously dropping or applying a transparent or translucent UV-curable paint containing a thermosetting agent onto a belt moving at a constant speed. It can be produced by forming a film-like material of a curable paint and irradiating the film with ultraviolet rays.

In addition, even in the case of "semi-cured transparent or translucent UV-curable paint containing a thermosetting agent" in this manufacturing method, although curing has progressed to some extent, there is still room for curing. It refers to a certain type of paint. In the laminated film manufacturing method II (the manufacturing method of the laminated film 70) described here, the intermediate layer film 56 is irradiated with ultraviolet rays in the subsequent process as well, and ultraviolet rays are irradiated twice in total. Even later, it is necessary to keep the intermediate layer film 56 in a semi-cured state (a state in which there is still room for curing) so that the curing is completed by heating during insert molding. Therefore, various irradiation conditions such as peak illumination intensity and integrated illuminance are determined for ultraviolet irradiation in this step, taking into consideration ultraviolet irradiation in subsequent steps.

Using the laminate 54 and the intermediate layer film 56 produced as described above, the laminate 54 is made of a decorative sheet impregnated with a transparent or translucent ultraviolet curing paint containing a thermosetting agent. An intermediate layer film 56 is attached onto the layer 52 to form a laminate 58 (FIG. 5(c)), and the laminate 58 is irradiated with ultraviolet rays. By irradiating the ultraviolet rays, the laminate 60 is formed by temporarily bonding the laminate 54 and the intermediate layer film 56, more specifically, a transparent or semi-transparent film containing a thermosetting agent is placed on one surface of the base film 32. A first layer 62 made of a decorative sheet containing a semi-cured transparent UV-curable paint, and an intermediate layer (second layer) made of a semi-cured transparent or translucent UV-curable paint containing a thermosetting agent. A laminate 60 (laminate b2) having a layer (layer) 64 is obtained (FIG. 5(d)).

The above-mentioned ultraviolet irradiation of the laminate 58 is advantageously carried out using a device capable of irradiating ultraviolet rays under vacuum pressure (UV curing vacuum pressurization device). By using such a device, it is possible to advance the curing of the UV-curable paint while promoting the penetration of the UV-curable paint into the decorative sheet, and the laminate 60 (laminate b2) will be obtained advantageously.

Further, by pasting a transparent synthetic resin film 44 on the intermediate layer 64 made of a semi-cured transparent or semi-transparent ultraviolet curing paint containing a thermosetting agent in the laminate 60 according to a known method. , the desired laminated film 70 is obtained (FIG. 5(e)). Note that, similarly to the above-mentioned manufacturing method I, it is also possible to use a translucent synthetic resin film instead of the transparent synthetic resin film 44.

Then, in the laminated films 30 and 70 obtained as described above, a synthetic resin base material is formed on the back surface (the surface on which the plurality of layers are not formed) of the base film 32 according to a known insert molding method. When molding No. 14, the heat during the molding (heat derived from the molten resin and the heated mold) acts on the thermosetting agent contained in the semi-cured material of the ultraviolet curable paint, and the semi-cured material This causes the curing to proceed. That is, by heating during insert molding, 1) the first layer 48 in the laminated film 30 and the first layer 62 in the laminated film 70 (a semi-cured product of a transparent or translucent ultraviolet curable paint containing a thermosetting agent); 2) layer 18 consisting of a decorative sheet containing a cured product of a transparent or translucent ultraviolet curable paint containing a thermosetting agent; The second layer 50 in 30 and the intermediate layer (second layer) 64 in the laminated film 70 (a layer made of a semi-cured transparent or translucent ultraviolet curable paint containing a thermosetting agent) contain a thermosetting agent. The intermediate layer 20 is made of a cured product of a transparent or translucent ultraviolet curable coating material. Then, on the synthetic resin substrate 14, a base film layer 16, a decorative layer 18 consisting of a decorative sheet containing a cured product of a transparent or translucent ultraviolet curable paint containing a thermosetting agent, and a thermosetting agent are formed. An ornament 12 is obtained by laminating an intermediate layer 20 made of a cured product of a transparent or semi-transparent ultraviolet curable paint, and a protective layer 22 made of a transparent synthetic resin film 44 in this order. .

As described above in detail, in the method for manufacturing a decorated resin product according to the present invention, since the laminated film used contains a semi-cured product of an ultraviolet curable coating material, the presence of such semi-cured material causes Laminated films have problems such as the decorative sheet breaking or shifting from the desired position depending on the external shape of the intended decorative resin product (the shape of the molding cavity in the molding die) during insert molding. The deformation can be advantageously carried out without occurrence of. Therefore, decorative resins with shapes that are difficult to manufacture using conventional insert molding methods using films with decorative sheets (for example, complex three-dimensional shapes, shapes with curved surfaces with large curvatures, etc.) Even products can be advantageously manufactured according to the present invention.

In addition, since the semi-cured product of the ultraviolet curable paint for the laminated film contains a thermosetting agent, the heat during insert molding advantageously promotes the curing of the semi-cured product, and the final product is cured. In the decorative resin products obtained by the process, the adhesion between the base film and the layer consisting of the decorative sheet containing the cured product of the ultraviolet curable paint and the adhesion between each layer on the base film are excellent. It becomes something.

Further, according to the manufacturing method of the present invention, the cured product of the ultraviolet curable paint is provided on the upper surface of the layer (the surface on the protective layer side of the same layer) consisting of the decorative sheet containing the cured product of the ultraviolet curable paint. Since it is possible to form an intermediate layer consisting of It is also possible to enjoy the advantage of being able to

The present invention has been described in detail above, but the present invention is capable of making various changes, modifications, improvements, etc., based on the knowledge of those skilled in the art, in addition to the above-described specific descriptions, without departing from the spirit of the present invention. It should be understood that additions may be made.

10 Instrument panel 12 Decorative resin products (ornaments)
14 Synthetic resin base material 16 Base film layer 18 Decoration layer 20 Intermediate layer 22 Protective layer

Claims (5)

Transparent or translucent UV-curable paints containing thermosetting agents, decorative sheets that can be penetrated by such UV-curable paints, transparent or translucent synthetic resin films, base films, and processing using synthetic resin substrates. As a manufacturing method for decorative resin products,
On one surface of the base film, i) a first layer consisting of the decorative sheet containing a semi-cured transparent or translucent ultraviolet curable paint containing the thermosetting agent; ii) the thermosetting A thin film of a transparent or translucent ultraviolet curable coating containing an agent is formed by irradiating ultraviolet rays to a semi-cured product of the ultraviolet curable coating, and is brought into close contact with the first layer by such ultraviolet irradiation. and iii) the protective layer made of the transparent or translucent synthetic resin film are laminated in this order to produce a laminated film,
Next, the synthetic resin base material is integrally molded on the other surface of the base film in the laminated film according to an insert molding method, and the first surface of the laminated film is heated by insert molding. 1) on one surface of the synthetic resin base material by curing a semi-cured product of a transparent or translucent ultraviolet curable paint containing the thermosetting agent constituting each of the second layer and the second layer. 2) a base film layer consisting of the base film; 2) a decorative layer consisting of the decorative sheet containing a cured product of a transparent or translucent ultraviolet curable paint containing the thermosetting agent; 3) containing the thermosetting agent. An intermediate layer composed of a cured product of a transparent or translucent ultraviolet curable paint, and 4) the above-mentioned protective layer, in which adjacent layers are laminated in close contact with each other in this order to produce a decorated resin product. ,
A method for producing a decorative resin product characterized by: The laminated film is
producing a laminate a1 in which the decorative sheet is laminated on one surface of the base film;
Using the laminate a1, on one surface of the base film, a layer consisting of the decorative sheet impregnated with a transparent or translucent ultraviolet curable paint containing the thermosetting agent, and the thermosetting layer. a step of producing a laminate a2 in which a layer consisting of a coating film of a transparent or translucent ultraviolet curable paint containing an agent is laminated in this order;
In the laminate a2, the transparent or translucent synthetic resin film is laminated on the surface of the layer consisting of a coating film of a transparent or translucent ultraviolet curable paint containing the thermosetting agent, and the laminate is in such a state. A step of irradiating a2 with ultraviolet rays,
The method for manufacturing a decorated resin product according to claim 1, which is manufactured through the following steps. The laminated film is
producing a laminate b1 having a layer made of the decorative sheet impregnated with a transparent or translucent ultraviolet curable paint containing the thermosetting agent on one surface of the base film;
a step of producing an intermediate layer film made of a transparent or translucent UV-curable paint containing the thermosetting agent and semi-cured by UV irradiation;
In the laminate b1, the intermediate layer film is laminated on the upper surface of the layer made of the decorative sheet impregnated with the transparent or translucent ultraviolet curable paint containing the thermosetting agent, and lamination in such a state. a step of producing a laminate b2 made of an integrated body of the laminate b1 and the intermediate layer film by irradiating the body b1 with ultraviolet rays;
Laminating the synthetic resin film on the surface of the intermediate layer film in the laminate b2;
The method for manufacturing a decorated resin product according to claim 1, which is manufactured through the following steps. The method for producing a decorated resin product according to any one of claims 1 to 3, wherein the decorative sheet is a wood sheet, an inorganic fiber sheet, an organic fiber sheet, or a Japanese paper sheet. The method for producing a decorated resin product according to any one of claims 1 to 3, wherein the ultraviolet curable paint is an unsaturated polyester resin paint.

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