JPH02150323A - Manufacture of uneven transferred molded object - Google Patents

Abstract

PURPOSE:To obtain effectively the objective molded object with many kinds of drawn unevenness by a method in which the film having the unevenness of female mold transferred from the carrier with the male mold unevenness of draw or mark, etc., is set in the mold, and while molding material is brought in contact with the uneven surface of the film, the material is molded, and then the film is peeled off therefrom. CONSTITUTION:The film with drawn unevenness is set in a mold so that the drawn uneven surface of the film is brought in contact with molding material. This setting process is used for e.g. muffle painting of injection molding. A printed film is temporarily fixed in the mold by using static electricity, etc. After the film with the drawn unevenness has been set in the mold, its molding is achieved, but if the peel after molding is difficult, the molded object is coated with normal peel treating agent (e.g. silicone peel treating agent, fluorine peel treating agent or wax), and is preferably dried. As the molding, injection molding is generally used.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a concave-convex transfer molded product, and more specifically, a method for producing a concavo-convex transfer molded product, and more specifically, a method for producing a concave-convex transfer molded product, and more specifically, a method for forming a product using a film having female concavities and convexities transferred from a carrier having male concavities and convexities such as diaphragms or marks. The present invention relates to a method for manufacturing a molded article having the unevenness of the film transferred onto the surface thereof. Note that "Irregularities such as shibori or marks" here refers to the shibori patterns of leather shibori or wood grain shibori, or letters, figures,
It refers to irregularities in the shape of marks such as symbols, etc., and hereinafter these are collectively referred to simply as aperture irregularities.

Molded products made of various synthetic resins and other materials are used in a wide variety and in large quantities in numerous fields. Recently, for example, in household goods, miscellaneous goods, etc., especially in high-end products, it has become desirable to express the above-mentioned concave and convex portions in a three-dimensional manner for decorative purposes and display purposes. However, in general, a method is adopted in which the drawing concavities and convexities are added to the mold itself during molding by engraving, etc., but the molds are expensive, and each mold is carved one by one according to the type and change of the drawing concavities and convexities. Molds must be prepared, which incurs great expense.

Therefore, the present inventors did not rely on engraving on the mold, etc.
We conducted extensive research on a method for forming apertures on the surface of a molded product, and found that by preparing a carrier with a predetermined male aperture and using a film with female apertures transferred from the carrier, this could be achieved. By using an arbitrary number of films with apertures reproduced in reverse from a single carrier, conventional molding molds can be used as is, and desired molded products with a variety of apertures can be efficiently produced. Find out what you can get,
The present invention has now been completed.

That is, in the present invention, a film having a female type aperture transferred from a carrier having a male type aperture is set in a mold, and after molding with a molding material in contact with the convex surface of the film, the above-mentioned The present invention provides a method for producing an uneven transfer molded article, which is characterized by peeling off the film.

The carrier used in the present invention is a carrier with apertures formed on the surface of the target molded product. For example, a paper mold, a heat-resistant resin film (polyester type, etc.), silicone rubber, aluminum foil, etc. are used, and the shape is also variable. It is not limited to a winding shape such as a paper type, but a shape provided on an endless stainless steel belt can also be adopted.

The film used in the present invention, on which the apertures of the carrier are transferred, can be obtained by, for example, applying a suitable resin composition onto the aperture surface of the carrier, then heating and drying or curing to form a film, and then applying the resin composition to the carrier. It can be created by peeling from.

The above-mentioned resin composition may be one that can be applied to a carrier to transfer its aperture with good reproducibility, and that can form a film that can withstand the temperature during molding described below for 7 minutes.
Any of these can be used, for example, a PVC plastisol composition (paste-like), preferably with a 100% solids content, or a PVC plastisol composition (in paste form), which has an OH group in part and can be made three-dimensional with an NGO group.
VC plastisol composition or PVC plastisol composition containing a crosslinking plasticizer or electron beam curable acrylic paint (oligomer), then PVC organosol with a solid content of 40% or more, emulsion paint, polyvinylidene fluoride or polyolefin Examples include solvent dispersion paints made from fine resin powders.

Although general solution-type paints (solid content 15 to 30%) can be used, the depth of the apertures transferred to the target molded product tends to be shallower than the original shape. A resin composition with a solid content of 100% is advantageous in setting into a mold because the bottom surface of the forming film (ie, the surface opposite to the convex surface for drawing) can be kept flat.

Further, the hardness of the resin composition can be varied over a fairly wide range, provided it is not extremely flexible. For example, P
In the case of VC systems, even if the plasticizer is flexible and has a plasticizer of around 60 PHR, it can be put to practical use if the molding material is something that can be processed at a relatively low temperature, such as polystyrene or polyethylene; on the other hand, if the plasticizer is around 15 PHR For hard ones,
It is recognized that it can be applied to a wide range of molding materials without any restrictions, and that it is possible to reproduce a clearer aperture.

When applying the resin composition to a carrier, it is usually 10 to 200μ
The amount of application may be selected so that a thick film is formed. The thickness of the film can be changed depending on the depth of the aperture opening, but in the case of general shallow leather drawing or wood grain drawing, the optimum thickness is 20 to 70 μm.

As a coating method, knife-over roll coating is particularly preferred, whereby the resin composition is applied thickly to the concave portions of the aperture of the carrier, and thinly to the convex portions. Methods such as reverse roll foot, in which the coating is applied almost uniformly to concave and convex areas, are also used because the fluidity of the resin composition brings the coating state almost the same as that of knife-over roll coating. can do.

After coating in this way, it is cured by heat drying or ultraviolet rays or electron beam irradiation under normal conditions to form a film, and then peeled off from the carrier to create a female aperture that is the opposite of the male aperture of the carrier. A film is obtained in which the aperture of the mold is transferred. Note that the heat resistance of the film can be further improved by the curing treatment.

Hereinafter, the manufacturing procedure of the uneven transfer molded article according to the present invention will be explained.

First, the film having the above-mentioned drawing concavities and convexities is set in a mold (in this case, the film is set so that the convex surface of the film is in contact with the molding material 1). Setting methods include, for example, the method of temporarily fixing the printing film inside the mold using static electricity, which is used in the so-called painting of injection molding, or the method of temporarily fixing the printing film inside the mold by Dai Nippon Printing Co., Ltd. In the thermojet method of coating a synthetic resin film on a mold, a method similar to the method of automatically supplying a synthetic resin film to a mold one frame at a time each time a split mold is opened and closed may be adopted. In this setting method, the apparatus employed in the supply method of Dai Nippon Printing Co., Ltd. can be applied as is or with simple modifications.

After setting the film with convex and concave convexities in the mold, molding is performed using an appropriate molding material.If the film can be easily peeled off after molding, there is no problem, but if it is difficult to peel off, it is usually (e.g., silicone-based release agents, fluorine-based release agents, waxes, fatty acids, fatty acid metal soaps, AC (low molecular weight) polyethylene, etc.)
It is preferable to apply and dry. The peeling agent is
Although it can be applied as it is by heating and melting it, it is effective to dilute it with a solvent or water (in the case of an emulsion type) to an appropriate concentration before applying it. As a coating method, general methods such as spraying and gravure coating can be applied, but it is desirable to coat the entire surface of the drawing irregularities extremely thinly (and as uniformly as possible. The treatment is not limited to the convex surface of the film, but can also be applied to the opposite side of the convex surface of the film in consideration of peeling from the mold and protection of the mold.Instead of applying a release agent, A similar release process can also be achieved by mixing a release agent into the formulation of the above-mentioned film resin composition and allowing the release agent to migrate (or bleed) onto the film surface by, for example, heating → cooling after film formation. It is possible to demonstrate the effect.

The next molding method is usually injection molding, but other methods such as RI M (IJ Action Injection Molding L), SMC (Sheet Molding Compound), etc. Alternatively, a compression molding method can also be applied.The position of the gate and the injection direction in injection molding are preferably selected so that the molding material can sequentially press the film from the center to the periphery of the inner surface of the mold.

There are no particular restrictions on the type of molding material, including thermoplastic PvC, polystyrene, polyethylene, polyvinylidene chloride, ABS resin, and other resins with high molding temperatures called engineering plastics, as well as thermosetting resins such as β- Polyimide resins that are molded on a stage and then heated to complete imidization are also included, and sintered metals, ceramics, etc. that are sintered after molding can also be used.

In addition, when manufacturing a three-dimensional object using a deep-bottomed mold, it is desirable to subject the set film to vacuum forming prior to molding so that the film follows the mold surface. The film needs to be thermoplastic so that it can be molded. On the other hand, in the case of a flat mold or a shallow mold, there is no need for vacuum forming, and a film with poor elasticity or a thermoset film can be used.

In this vacuum forming, degassing holes etc. are provided in the mold, the film is heated, and then pulled under vacuum to make the film follow the concave surface of the mold.In this case, the equipment used in the thermojet method can be used as is. Alternatively, it can be applied with slight modification. Note that there is no problem if there is a degassing hole for vacuum forming in the mold cavity, but if the film is pressed against the mold concave surface by resin pressure (in this case, the film must be split so that the air between the film and the mold can escape). Deaeration holes allow minute degassing from the mating surfaces of the mold,
Alternatively, it is desirable to provide a groove in the mold matching portion.

In addition, in the case of injection molding, it is also possible to preform the film in advance and attach it to the mold, but in this case,
Even if the preforming mold is made slightly smaller than the inner dimensions of the injection mold for the purpose of facilitating installation, the resin temperature and mold humidity during injection molding may soften the resin during molding. The pressure will cause the film to be stretched until it is in close contact with the inner surface of the mold.

After the molding is performed in this manner, the mold is generally cooled to an appropriate temperature and demolded, and then the film on the surface is peeled off to obtain the desired molded product having the desired drawing irregularities.

According to the present invention having the above-described configuration, for example, a plurality of films can be created from one carrier, and a molded product having a desired drawing unevenness can be efficiently manufactured using the films.
Moreover, manufacturing costs can be reduced by avoiding the conventional work of engraving the concave surface of the mold. The resulting molded product is suitable for use in high-end products that require decorative effects or display purposes, and can be used, for example, in molded parts of high-end cosmetics, cabinets for electrical appliances, stationery, miscellaneous goods, etc. .

Next, the present invention will be explained in more detail with reference to Examples.

Example 1 (1) Resin composition for film Stir and mix the following parts of the ingredients.

Ingredients Part by weight PVC (
Kanevinyl Paste PSH-2 manufactured by Hitomiya Kagaku Kogyo Co., Ltd.
0) ・・・・・・・・・100 diundecyl phthalate ・・・・・・・・・ 3
0 Mineral Spirits ・・・・・・・・・
・20Ba-Zn stabilizer...
・・・・ ISn stabilizer ・・・
・・・・・・ 0.5(2) Film having unevenness The composition of (1) above was coated on the surface of a paper mold having a male leather film with a knife over roll coater at 60.9/7n2.
After coating the film in an amount of
A film of 0 μm is obtained.

(3) Concave-convex transfer molded product The film of (2) above was set along the female die of an injection mold, and ABS resin was injected onto it at a resin temperature of 210°C and an injection pressure of 900 kQ/32 to form a surface A 3 gi+ ABS resin molded product with a wall thickness of 3 gi+ is obtained by laminating a film on the surface, and then it is cooled and demolded, and then the film is peeled off to form the desired unevenness with the film's leather film transferred to the surface. A transfer molded product can be obtained.

Claims (1)

[Claims] 1. A film having female-shaped unevenness transferred from a carrier having male-shaped unevenness such as an aperture or mark is set in a mold,
A method for producing a concavo-convex transfer molded article, which comprises molding the film while bringing a molding material into contact with the concavo-convex surface of the film, and then peeling off the film. 2. The manufacturing method according to claim 1, which comprises performing differential pressure molding on the film before molding the molding material when a three-dimensional molded product is manufactured using a deep-bottomed mold. 3. The film to which the female mold's unevenness has been transferred is obtained by coating a resin composition on the male mold's uneven surface of the carrier, then heating and drying or curing it to form a film, and then peeling it off from the carrier. The manufacturing method according to claim 1 or 2.