JPH03218824A - Sheet for shaping and shaping method using same - Google Patents

Abstract

PURPOSE:To manufacture a sheet for shaping of high resistance to heat by providing a deposit layer on a stereoscopic pattern surface of a thermoplastic layer provided with stereoscopic pattern on its surface. CONSTITUTION:A deposit layer 2 of a sheet S for shaping is provided on the surface of a stereoscopic pattern 1a of a thermoplastic resin layer 1 having the stereoscopic pattern 1a on its surface, and stereoscopic pattern 2a almost same as said stereoscopic pattern 1a is formed on the surface of the deposit layer 2. As for the thermoplastic resin layer 1, resin of proper resistance to heat and deposition properties and preferably to be extrusion laminated, and for instance, ester, polyamide, polyvinyl chloride and the like can be used. As for the stereoscopic pattern 1a of the thermoplastic layer 1, embossing or the like can be applied. As for the deposit layer 2, a material having resistance to heat higher than that of the thermoplastic layer 1 and durable for the temperature in the shaping process, for instance, metal such as aluminum or the like, various kinds of ceramics or the like are included to be suitable for use. As the stereoscopic pattern is applied onto the thermoplastic resin layer, on which the deposit layer is provided to upgrade resistance to heat of the sheet for shaping to enhance resistance to heat by 20-30 deg.C.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a shaping sheet and a shaping method using the same. [Prior art and problems] Conventionally, methods of imparting patterns to the surface of thermoplastic resin molded products include (1) a method of imparting patterns such as mirror semi-matte, manoto, hairline, etc. using a mold; (2) a method of imparting patterns such as mirror semi-matte, manoto, hairline, etc. A method of painting and molding using printing foil (printed plastic film), (3) as in Utility Model Application Publication No. 1-105960,
A method of integrally molding a printed thermoplastic film (label) into a molded product, (4) As disclosed in JP-A-62-116197 and JP-A-1-188399, three-dimensional patterns are produced from printed sheets or embossed sheets. (5) A method of transferring the three-dimensional pattern to a thermoplastic resin using a releasable transfer sheet, (5) Imprinting using a releasable fine embossed sheet as disclosed in JP-A-192600. There are known methods to do this.

However, since method (1) uses a mold, there is a limit to the pattern itself, making it impossible to create precise patterns, and the cost is high because molds must be prepared for the number of patterns. Furthermore, changing the pattern requires replacing the mold, which makes the work complicated and poses a problem in terms of work efficiency. (
The purpose of method 2) is painting, rather than adding a pattern based on glossiness or directionality using the difference in unevenness. Method (3) is to integrally mold the label onto the container or the like. Methods (4) and (5) are used when the transfer or imprinting sheet and the molded product resin are of the same type, they may fuse together (at high temperatures) or the depth of the pattern is shallow (at low temperatures). ), it is difficult to obtain the desired beautiful pattern.

(Means for Solving the Problems) In view of the above circumstances, the present inventors have conducted extensive research to solve the above problems, and as a result, have arrived at the present invention.

That is, the first aspect of the present invention is a forming sheet characterized by providing a vapor deposition layer on the three-dimensional pattern surface of a thermoplastic resin layer having a three-dimensional pattern on the surface; A sheet for shaping, characterized in that a thermoplastic resin layer having a three-dimensional pattern on the surface and having lower heat resistance than the base material is provided thereon, and a vapor deposition layer is further provided on the surface having the three-dimensional pattern, The third aspect of the present invention is a shaping method using the above-mentioned shaping sheet.

The present invention will be explained based on drawings showing embodiments.

1 to 4 are schematic cross-sectional views showing the shaping sheet of the present invention, respectively.

The shaping sheet (S) in FIG. 1 has a three-dimensional pattern (1a) on the surface of the thermoplastic resin layer (1).
A vapor deposited layer (2) is provided on the surface, and the surface of the vapor deposited layer (2) is provided with a three-dimensional pattern (2a) that is substantially the same as the three-dimensional pattern (1a).
) is formed.

The shaping sheet (S) shown in FIG. 2 has a base material (3) provided on the back side of the thermoplastic resin layer (1) of the shaping sheet shown in FIG. The shaping sheet (S) shown in FIG. 3 has a three-dimensional pattern (2a) surface of the vapor deposited layer (2) of the shaping sheet shown in FIG. Vapor deposited layers (5) are sequentially provided. A three-dimensional pattern (4a) substantially the same as the three-dimensional pattern (2a) of the vapor-deposited layer (2) is transferred and formed on the contact surface of the release layer (4) with the vapor-deposited layer (2). (A similar three-dimensional pattern is inevitably formed on the colored layer and/or the vapor deposited layer (5).) (P) indicates the peeled surface.

The shaping sheet (S) shown in FIG. 4 further includes a release layer (4), a colored layer and/or a three-dimensional pattern (2a) surface of the colored layer (2) of the shaping sheet shown in FIG. A vapor deposition layer (5) and an adhesive layer (6) are provided in this order. The bonding surface of the release layer (4) with the vapor deposited layer (2) has a three-dimensional pattern (2a
) A three-dimensional pattern that is approximately the same as that is transferred and formed. (Similar three-dimensional patterns are inevitably formed on the colored layer and/or the vapor deposited layer (5) and the adhesive layer (6), respectively.) (P) indicates the peeled surface. The thermoplastic resin layer (1) is not particularly limited as long as it has appropriate heat resistance and vapor deposition properties, but it is preferably a resin that can be extruded and laminated, such as polyethylene terephthalate (PET), polybutylene terephthalate ( Examples include polyesters such as PBT), polyamides, polymethylpentene (TPX), polypropylene, and polyvinyl chloride. The thickness of the resin layer (1) is usually 15
A suitable thickness is about 80 μm.

The base material (3) must also be able to withstand the temperature in the molding process and have higher heat resistance than the thermoplastic resin (1), preferably having toughness, dimensional stability, thermal conductivity, etc. For example, polyesters such as biaxially oriented polyethylene terephthalate and polybutylene terephthalate, aromatic polyamides, polyimides, paper, metal foils,
Examples include various laminates. Thickness is usually 9-100
Approximately μm is appropriate. The base material (3) is a thermoplastic resin layer (
It is effective for reinforcing 1), increasing dimensional stability, and forming a pattern that does not lose its shape.

The three-dimensional pattern (Ia) of the thermoplastic resin layer (1) is formed using the empos method, JP-A-62-116197, JP-A-1-1883.
Known methods such as those disclosed in No. 99, No. 1-192600, etc. can be used.

As the vapor deposition layer (2), a material is used that has higher heat resistance than the thermoplastic resin (1) and can withstand the temperature in the molding process, such as metals such as aluminum, various ceramics, etc. In addition to ordinary vacuum deposition, methods such as vacuum processing such as sputtering and ion plating can be used. The thickness of the vapor deposited layer (2) may be appropriately determined by taking into consideration the heat resistance of the thermoplastic resin (1), the temperature of the molding process, etc., but it is usually appropriate to use about 100 to 800 people.

As the release layer (4), a material having heat resistance that can withstand the temperature of the molding process is used, such as silicone resin, long chain alkyl acrylate, long chain alkyl carbamate, long chain alkyl amide, and combinations of these and the second component. Known exfoliating materials such as copolymers can be used. The peeling layer (4) not only facilitates peeling from the vapor deposited layer (2), but also allows the three-dimensional pattern (4a) transferred from the three-dimensional pattern (2a) of the vapor deposited layer (2) on its surface to be removed. The colored layer and/or vapor deposited layer (5) and adhesive layer (6) transferred and attached to the surface of the molded body in the molding process complete the molding process, and after molding, it acts as a surface protective layer. It is something that works.

The vapor deposited layer and/or the colored layer (5) adds color to the three-dimensional pattern that has been formed.The colored layer contains various patterns, characters, marks, symbols, letters, etc. Needless to say, durable vapor deposition materials and inks such as those mentioned above are used. For the adhesive layer (6), a material with good adhesion to the molded product in the molding process is used, such as acrylic resin, styrene resin, olefin resin, vinyl chloride-vinyl acetate copolymer, rubber resin, etc. It will be done. The appropriate thickness is usually about 5 to 20 g/rrf. In order to perform shaping using the shaping sheet of the present invention, the shaping sheet is brought into contact with a molten thermoplastic resin, and the sheet is peeled off on the surface of the vapor deposited layer (2) or release layer (4). For example, injection molding, compression molding,
Examples include blow molding, extrusion (laminate) molding, and the like. However, in the case of a shaping sheet having an adhesive layer (6) as shown in FIG. 4, it can also be applied to vacuum forming, etc.

Thermoplastic resins to be molded include polystyrene, high impact polystyrene, polymethyl methacrylate,
Examples include AS resin, ABS resin, MBS resin, polyester resins such as PET and PBT, polypropylene, polyvinyl chloride, and polyoxymethylene.

FIG. 5 shows a state in which a mold is formed using the molding sheet (S) shown in FIG. ), by injection molding thermoplastic resin,
Shaping sheet (S) and molded body (7) as shown in Figure 5 (A)
After cooling, the peeled surface (P), that is, the surface of the three-dimensional pattern (2a) of the vapor deposited layer (2), is used to peel off and remove the three-dimensional pattern (S) of the vapor deposited layer (2). Molded object (7) having a three-dimensional pattern (7a) almost the same as 2a) on its surface
is obtained. FIG. 6 shows a shape m to be shaped using the shaping sheet (S) shown in FIG. 4, and by the same operation as in FIG. 5, as shown in FIG. 6(A), An integrated product of the seal (S) and the molded body (7) is obtained, and after cooling, the peeled surface (P),
That is, when the vapor deposited layer (2) is removed from the surface of the three-dimensional pattern (2a), the release layer (4), colored layer and/or vapor deposited layer (5) having the three-dimensional pattern (4a) on the surface becomes the adhesive layer (6). ), an integrated molded body (7) is obtained.

Incidentally, a mold release protective layer may be provided on the three-dimensional patterned surface of the vapor deposited layer of the mold forming sheet shown in FIGS. 1 and 2, if necessary. Furthermore, when a base material is used, in order to improve the adhesion with the thermoplastic resin layer, an anchor coating, corona discharge treatment, ozone treatment, flame treatment, etc. may be applied alone or in combination.

〔Example〕

EXAMPLES Hereinafter, the present invention will be explained in more detail based on Examples, but the present invention is not limited to these in any way.

Example 1 A biaxially stretched polyester film (Toyobo Ester E5100, thickness 38 urn) was coated with an isocyanate anchor coat (Dainippon Ink & Chemicals, AC-5) as a base material.
0OA, coating amount 0.5g/%), and corona discharge treatment (30W/%) was applied to the anchor coated surface.
/s+in), and using a T-die extrusion laminating machine (screw diameter 115tm, L/D25), polyester resin (Polyplastisox, Duranex 6
00FP) at T-die exit temperature 300℃, thickness 30ttm
It was extruded with On the other hand, a polypropylene sheet (thickness: 30 μm) with a predetermined three-dimensional pattern is placed so that its three-dimensional pattern surface is in contact with the extruded resin, and the extruded resin is sandwiched in the center and pressed with press rolls, and then cooled. After being cooled by rolls, the laminate was wound up as one piece by a winder.

The sheet was peeled off from the extruded laminate resin surface of the rolled laminate to obtain a laminate sheet in which the desired three-dimensional pattern was accurately copied onto the laminate resin surface.

Next, aluminum bonding (thickness: 400 mm) was applied to the three-dimensional patterned surface of this laminated sheet by a conventional method to obtain a sheet for shaping.

This shaping sheet was set so as to be continuously fed into the movable mold of the in-mold molding machine, and the same polyester resin (Duranex 60
When a composition containing 0FP) as the main component and 4% by weight of black pigment was injection molded, the result was a 3.5 mm thickness with slight differences in gloss and directionality on the surface without causing any fusion or deformation. A plate with a textured three-dimensional pattern was obtained. Example 2 A release layer containing a silicone resin was coated at 0.6 g/rrf on the vapor-deposited surface of the vapor-deposited laminated sheet obtained in Example 1, and then printed using a glittering pigment by a conventional method, and then printed by a conventional method. An acrylic adhesive was applied and dried to obtain a sheet for shaping.

The obtained shaping sheet was set to be continuously fed out into the movable mold of an in-mold molding machine in the same manner as in Example 1, and polyester resin DURANEX 600FP was injection molded, but no fusion or deformation occurred. In addition to a beautiful printed pattern, we were able to obtain a polyester plate with an extremely high texture, which had a superimposed background pattern with subtle differences in gloss and directionality, without causing any problems. [Function/Effect] As mentioned above, the shaping sheet of the present invention has a structure in which a three-dimensional pattern is imparted to a thermoplastic resin layer by a known method, and a vapor deposited layer is further provided on the surface of the thermoplastic resin layer. The heat resistance of the sheet for use is improved by 20 to 30°C, and as a result, even resins of the same type as the thermoplastic resin or resins with the same heat resistance or 20 to 30°C higher can be effectively shaped. Can be done. Thus,
The range of resins that can be molded using the molding sheet is greatly expanded, and workability and productivity are dramatically improved.

[Brief explanation of drawings]

1 to 4 are schematic cross-sectional views showing embodiments of the shaping sheet of the present invention, and FIGS. 5(A), (B) and 6(A), (B) are respectively FIG. 2 is a schematic cross-sectional view for explaining the molding method. 1...Thermoplastic resin layer, 1
a... Three-dimensional pattern 2... Vapor deposition layer, 2a...
Three-dimensional pattern 3...Base material, 4...Release layer 4
a... Three-dimensional pattern, 5... Colored layer and/or vapor deposition layer 6... Adhesive layer, 7... Molded body S...
Shaping sheet, P...Peeling surface 1 Fig. 1 Fig. 2 Fig. 3 l Fig. 4 Fig. 5 (^)

Claims (9)

[Claims] 1. A mold-forming sheet comprising a thermoplastic resin layer having a three-dimensional pattern on its surface, and a vapor deposition layer provided on the three-dimensional pattern surface. 2. 2. The shaping sheet according to claim 1, further comprising a release layer provided on the surface of the vapor deposited layer, and further provided with a colored layer and/or a vapor deposited layer on the surface. 3. 3. The shaping sheet according to claim 2, wherein an adhesive layer is provided on the surface of the colored layer and/or the vapor deposited layer. 4. 1. A sheet for shaping, characterized in that a thermoplastic resin layer having a three-dimensional pattern on its surface and having lower heat resistance than the substrate is provided on a base material, and further a vapor deposition layer is provided on the surface of the three-dimensional pattern. 5. 5. The shaping sheet according to claim 4, further comprising a release layer provided on the surface of the vapor deposited layer, and further provided with a colored layer and/or a vapor deposited layer on the surface. 6. The shaping sheet according to claim 5, wherein an adhesive layer is provided on the surface of the colored layer and/or the vapor deposited layer. 7. The shaping sheet according to item 1 or 4 is brought into contact with a molten thermoplastic resin, the three-dimensional pattern on the surface of the vapor deposited layer of the shaping sheet is transferred to the surface of the thermoplastic resin, and then cooled. and then peeling and removing the shaping sheet from the surface of the thermoplastic resin. 8. The shaping sheet according to item 2 or 5 is brought into contact with the thermoplastic synthetic resin in a molten state, and then cooled, and the three-dimensional pattern on the surface of the vapor deposited layer is transferred from the vapor deposition surface of the shaping sheet. A molding method characterized in that the peeling layer, the colored layer and/or the vapor deposited layer on the surface thereof are peeled off and transferred to the surface of the thermoplastic resin. 9. The shaping sheet described in item 3 or 6 is brought into contact with the thermoplastic synthetic resin in a molten state, and then cooled, and the three-dimensional pattern on the surface of the vapor deposited layer is transferred from the vapor deposition surface of the shaping sheet. A molding method characterized by peeling off a peeling layer, a colored layer and/or a vapor deposited layer on the surface thereof, and an adhesive layer on the surface thereof, and adhering and transferring them to the surface of the thermoplastic resin.