JPH05193017A - Manufacture of vinyl chloride resin metallic molded form - Google Patents

Abstract

PURPOSE:To provide the manufacture of a vinyl chloride resin metallic molded form having the excellent physical properties of a surface even when the molded form is press-molded in a three-dimensional shape, in which no whitening and cracking is generated and which has a Japanese lacquer-like specular gloss surface having profoundness and a delustered surface and has superior scratch resistance and stain resistance. CONSTITUTION:The surface is of a colorless transparent or colored transparent vinyl chloride resin sheet, on the rear side a specified patterns is printed, is coated with UV curing coatings, and irradiated with UV rays and cured, and the rear side and a metal plate 4 are bonded. The bonded sheet and metal plate are punched in a desired shape. The cavity surface 10 of a mold is specular-finished or delustering-finished previously, and the mold and a vinyl chloride resin metal plate 6 are heated at 40-100 deg.C, and formed in a three- dimensional shape through a press method. The coating and curing of UV ray curing coatings can also be conducted through a process after the mold and the metal plate 6 are formed in the three-dimensional shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a vinyl chloride resin metal molded product used as a decorative material for refrigerators and furniture, interior parts for automobiles and the like.

[0002]

2. Description of the Related Art Conventionally, vinyl chloride resin metal molded products having a three-dimensional shape have been used for refrigerators, furniture, interior parts of automobiles and the like.

As a conventional method for producing a vinyl chloride resin metal molded product, for example, a vinyl chloride resin decorative sheet is attached by a vacuum pressing method after molding a metal plate into a three-dimensional shape. There is a method, or a method in which a soft vinyl chloride resin decorative sheet is attached to a steel plate and then press-molded with a mold at room temperature.

However, regarding the former manufacturing method,
When a metal sheet is molded into a three-dimensional shape and then laminated with a vinyl chloride resin decorative sheet, trimming of the sheet and end treatment after lamination are required, so only a thin sheet can be used, and However, because of its thin thickness, a vinyl chloride resin metal molded product with a lacquer-like depth and mirror-like gloss could not be made.

On the other hand, with regard to the latter manufacturing method, after the vinyl chloride resin decorative sheet is attached to a metal plate and molded by a pressing method using a mold at room temperature, the vinyl chloride resin decorative sheet used is processed. In consideration of the property, it must be a soft one, that is, a vinyl chloride resin decorative sheet with a high plasticizer content. However, because of that, the adhesion between the vinyl chloride resin decorative sheet and the UV-curable paint is insufficient, whitening or cracks occur on the surface, or the surface properties such as scratch resistance are poor. There was a problem.

[0006] Various methods have been used to give a pattern to the surface of a plastic molded product by a special transfer method, but the productivity is poor, and there are problems in terms of efficiency and cost.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to obtain excellent surface properties even when press-formed into a three-dimensional shape, and to prevent whitening or cracking. Another object of the present invention is to provide a method for producing a vinyl chloride resin metal molded product which has a deep lacquer-like mirror-like glossy surface and a matte surface and is also excellent in scratch resistance and stain resistance.

[0008]

Means for Solving the Problems The means provided by the present invention for achieving the above-mentioned object are, namely, a three-dimensional shape, a vinyl chloride resin decorative sheet on one side and a metal plate on the other side. In the method for producing a vinyl chloride resin metal molded article, the vinyl chloride resin decorative sheet is coated with an ultraviolet curable coating on its front side and cured by irradiation with ultraviolet rays, and then the vinyl chloride resin decorative sheet is formed. Of the vinyl chloride resin metal molded product, characterized in that the back side of the metal plate and the metal plate are adhered, punched into a desired shape after that, and then molded into a three-dimensional shape by a pressing method using a mold. Is the way.

Alternatively, in a method for producing a vinyl chloride resin metal molded article having a three-dimensional shape, a vinyl chloride resin decorative sheet on one side and a metal plate on the other side,
The back side of the vinyl chloride resin decorative sheet is adhered to the metal plate, which is then punched into a desired shape, and then molded into a three-dimensional shape by a pressing method using a mold, and then the vinyl chloride resin. A method for producing a vinyl chloride resin metal molded article, which comprises a step of applying an ultraviolet curable coating material to the front side of a decorative sheet for making and curing it by irradiation of ultraviolet rays.

In a preferred embodiment, the temperature of the mold is 30 to 110 when molding into the three-dimensional shape.
The method for producing a vinyl chloride resin metal molded article is characterized in that the molding is carried out by heating to 40 ° C, more preferably 40 to 100 ° C.

More preferably, when molding the vinyl chloride resin metal plate at a temperature of 30 to 110 ° C. when molding into the three-dimensional shape,
More preferably, the method for producing a vinyl chloride resin metal molded product is characterized in that the molded product is formed after heating to 40 to 100 ° C.

More preferably, the vinyl chloride resin decorative sheet is made of a vinyl chloride resin having a plasticizer content of 20 PHR or less, more preferably 15 PHR or less. It is a method of manufacturing a product.

In another preferred embodiment, the method for producing a vinyl chloride resin metal molded product is characterized in that, when molding into the three-dimensional shape, the cavity surface of the mold has a mirror finish. ..

Alternatively, in the above-mentioned method for producing a vinyl chloride resin metal molded article, the cavity surface of the mold has a matte finish when the three-dimensional shape is molded.

The present invention will be described in more detail below with reference to the drawings. (FIG. 1) is a schematic view showing a configuration example of a vinyl chloride resin metal plate obtained by laminating the vinyl chloride resin decorative sheet and the metal plate. Here, as the vinyl chloride resin decorative sheet, a transparent (colorless or colored) vinyl chloride resin sheet 1 having a pattern (pattern layer 2) printed on the back side of the original fabric is used.

Besides the above, as the vinyl chloride resin decorative sheet, there is a pattern (picture layer 24) on the back side of the transparent (colorless or colored) vinyl chloride resin sheet 23 and a solid pattern (from above). A solid pattern layer 25) is printed (FIG. 4), a pattern (picture layer 22) is simply printed on the front side of the original sheet of the colored vinyl chloride resin sheet 21 (FIG. 5), or Colored vinyl chloride resin sheet 26
Various patterns are conceivable, such as one in which a pattern (pattern layer 27) is printed on the front side of the original fabric and another transparent vinyl chloride resin sheet 28 is thermally laminated (FIG. 6). However, the examples of (FIG. 1) and (FIG. 6) are the most excellent in terms of depth and feeling of flesh. The vinyl chloride resin decorative sheet of the present invention uses a vinyl chloride resin having a low plasticizer content.

The picture layers 2, 22, 24 and 27 are formed by printing a predetermined picture on a vinyl chloride resin sheet by a gravure printing method using an ink of vinyl chloride-vinyl acetate copolymer system. .. The thickness is preferably about 10 μm or less in consideration of the printing method used, the characteristics of the ink, and the way in which the feeling of flesh is exhibited.

Further, the ultraviolet curable coating material 3 may be any one having a high adhesiveness to the vinyl chloride resin, but it is desirable that the ultraviolet curable coating material 3 having a large amount of resin solid component and a low viscosity has the above-mentioned depth and thickness. It is advantageous in giving a feeling. Also, the curing hardness of the coating film is preferably not too high,
A pencil hardness of about HB to 4H is sufficient. As the resin system, an ordinary acrylic resin-based UV-curable coating material containing oligoester acrylate or urethane acrylate as a main component is suitable. Considering the easiness of application and curing, and the appearance of depth, it is appropriate to apply a thickness of about 60 μm or less so that ultraviolet rays are uniformly and sufficiently irradiated even on the surface of a three-dimensional molded product. And cure.
If dirt such as an oil film adheres to the surface before coating, it is necessary to perform pretreatment such as degreasing and washing.

As the metal plates 4 and 29, steel plates or aluminum plates whose surfaces have been subjected to surface treatment such as chemical conversion treatment or plating treatment are used. The metal plates 4 and 29 have appropriate rigidity and play the role of a support as a molded product, and from the viewpoint of weight and workability, those having a thickness of 0.2 to 1.0 mm are suitable.

The vinyl chloride resin decorative sheet 12 that has been subjected to the above-mentioned treatment is adhered to the metal plate 4. Adhesive 5
As the material, known materials can be used, and for example, sufficient materials can be obtained by using a known adhesive such as polyester or urethane.

After the vinyl chloride resin metal plate 6 completed by the above steps is punched into a predetermined shape, one or both of the metal mold and the vinyl chloride resin metal plate 6 is press-molded to obtain a predetermined three-dimensional shape. obtain. In the example shown in FIG. 2, the vinyl chloride resin decorative sheet side is directed to the lower mold 8, and press molding is performed between the heated upper mold 7 and the lower mold 8. A known method can be used for heating the mold, and not only the electric heater 9 but also steam, hot water, or the like may be used.

[0022]

In general, vinyl chloride resin becomes harder as the plasticizer content decreases, but on the other hand, it becomes gradually brittle. Moreover, if the thick vinyl chloride resin decorative sheet is forcibly bent, whitening or cracking may occur.

However, in the method for producing a vinyl chloride resin metal molded product of the present invention, a vinyl chloride resin having a small plasticizer content is used by heating one or both of the mold and the vinyl chloride resin metal plate. Even if it does not whiten or crack, it can be easily press-formed into a three-dimensional shape.

At this time, if the cavity surface 10 of the lower die 8 (the surface that comes into contact with the vinyl chloride resin metal plate 6) is mirror-finished, the vinyl chloride resin metal molded product 11 whose surface finish has a mirror gloss. Can be obtained. Alternatively, if the cavity surface 10 of the lower mold 8 is matte-finished, a vinyl chloride resin metal molded product 11 having a matte surface finish can be obtained.

When a transparent vinyl chloride resin having a large thickness (for example, 0.8 mm) and a small plasticizer content is used, the cavity surface of the mold (the surface in contact with the vinyl chloride resin metal plate 6) is mirror-finished. Then, when the metal mold or the vinyl chloride resin metal plate 6 is heated and press-molded, the surface has a lacquer-like specular gloss with a particularly deep surface due to the heat and pressure during molding, and the surface has excellent physical properties. A strong vinyl chloride resin metal molded product can be obtained.

And again, thick wall (for example, 0.8 mm)
When a transparent vinyl chloride resin containing a small amount of plasticizer is used, the cavity surface of the mold (the surface in contact with the vinyl chloride resin metal plate 6) is matte-finished and the mold or the vinyl chloride resin metal plate 6 is used. When heated and press-molded, the surface finish is matte due to the heat and pressure at the time of molding, and a strong vinyl chloride resin metal molded product having excellent surface properties can also be obtained.

Further, when a protective layer of an ultraviolet curable coating material is provided on the surface of the coating material, it is possible to obtain a material having excellent scratch resistance and stain resistance.

[0028]

【Example】

<Example 1> 0.3 mm in thickness and 0 PH in plasticizer content
A pattern layer 2 (thickness: 3 μm) was formed on one surface of the R vinyl chloride resin decorative sheet 1 by a gravure printing method using an ink of vinyl chloride-vinyl acetate copolymer system.

Next, an ultraviolet curable coating material 3 was applied (thickness: 10 μm) to the other surface of the vinyl chloride resin decorative sheet 1 and then irradiated with ultraviolet rays to be cured.

Next, as the metal plate 4, an aluminum plate having a thickness of 0.7 mm (JIS A
5052) is coated with urethane adhesive 5 and adhered to the surface of the picture layer 2 on the vinyl chloride resin decorative sheet 1.

After the vinyl chloride resin metal plate 6 obtained through the above steps is punched into a predetermined shape, both molds are heated (60 ° C.) with the vinyl chloride resin surface facing the lower mold 8. That is, press molding was performed using the upper mold 7 and the lower mold 8.

The cavity surface 10 of the lower die 8 (the surface that contacts the vinyl chloride resin metal plate 6) was mirror-finished in advance. The vinyl chloride resin metal plate 6 was heated (60 ° C.) in advance before press molding.

<Example 2> The same procedure as in Example 1 was carried out except that the plasticizer content of the vinyl chloride resin was changed to 5 PHR.

<Example 3> The same procedure as in Example 1 was carried out except that the surface of the lower die 8 in contact with the vinyl chloride resin metal plate 6 (cavity surface) was matte finished.

<Example 4> A colored vinyl chloride resin sheet having a plasticizer content of 12 PHR and a thickness of 0.1 mm was printed with a wood grain pattern, and then a plasticizer content of 10 PH was applied.
A transparent vinyl chloride resin sheet having a thickness of R and a thickness of 0.1 mm was attached to produce a vinyl chloride resin decorative sheet. Next, the vinyl chloride resin decorative sheet was attached to the surface of an electrogalvanized steel sheet having a thickness of 0.8 mm using the adhesive. After punching this into a predetermined shape, it was heated to 80 ° C. and press-molded into a three-dimensional shape using a mold heated to the same temperature. An ultraviolet-curable coating material was applied to the front surface of the obtained molded product so as to have a thickness of 50 μm, and then ultraviolet rays were uniformly and sufficiently irradiated to cure the coating film.

<Comparative Example 1> The procedure of Example 1 was repeated, except that the plasticizer content of the vinyl chloride resin was 30 PHR.

<Comparative Example 2> The same procedure as in (Example 1) was performed except that the upper die 7, the lower die 8 and the vinyl chloride resin metal plate 6 were molded without heating.

According to the above (Example 1), (Example 2) and (Example 4), both of them are excellent in depth of the surface, have a lacquer-like specular gloss, and are excellent in the physical properties of the surface and durable. In addition, a vinyl chloride resin metal molded product 11 having sufficient adhesion between the ultraviolet curable coating material and the vinyl chloride resin decorative sheet was obtained. Further, according to the above (Example 3), a vinyl chloride resin metal molded product 11 having a matte surface finish and the same other quality as those of the above (Example 1) and (Example 2) was obtained. Further, according to (Example 4), since the printed pattern has a transparent layer of about 150 μm, the surface is particularly rich in depth, and the surface is not only extremely smooth and excellent in image clarity, A vinyl chloride resin metal molded product 11 having an excellent hardness of about 3H and a sufficient adhesion between the ultraviolet curable coating material and the vinyl chloride resin decorative sheet was obtained.

On the other hand, the vinyl chloride resin metal molded product 11 of Comparative Example 1 was inferior in scratch resistance. Further, according to the above (Comparative Example 2), whitening and cracking occurred in the vinyl chloride resin metal molded product 11.

[0040]

As described above, according to the present invention, printing on a film, laminating, laminating on a metal plate, etc. can all be continuously performed in a web form, so that there is no waste in the process and the cost is low. Is advantageous. Even if it is press molded into a three-dimensional shape, it has excellent surface properties, does not whiten or crack, has a deep lacquer-like mirror-like glossy finish or a matte finish, and has scratch resistance and stain resistance. In addition, since a vinyl chloride resin containing a small amount of a plasticizer is used, it is possible to secure a quality having excellent adhesion to an ultraviolet curable coating. From the above, it was possible to provide a manufacturing method capable of obtaining a vinyl chloride resin metal molded product with excellent quality, high productivity, and low cost.

[0041]

[Brief description of drawings]

FIG. 1 is an explanatory view showing a vinyl chloride resin metal plate according to an embodiment of the present invention.

FIG. 2 is an explanatory view showing how a vinyl chloride resin metal plate of FIG. 1 according to an embodiment of the present invention is press-formed.

FIG. 3 is an explanatory view showing a vinyl chloride resin metal molded product obtained after (FIG. 2) according to one embodiment of the present invention.

FIG. 4 is an explanatory view showing a vinyl chloride resin decorative sheet according to another embodiment of the present invention.

FIG. 5 is an explanatory view showing a vinyl chloride resin decorative sheet according to another embodiment of the present invention.

FIG. 6 is an explanatory view showing a vinyl chloride resin decorative sheet according to still another embodiment of the present invention.

FIG. 7 is an explanatory view showing a vinyl chloride resin metal plate using a vinyl chloride resin decorative sheet according to yet another embodiment of the present invention (FIG. 6).

[Explanation of symbols]

 1, 23, 28 ... Transparent vinyl chloride resin sheet 2, 22, 24, 27 ... Ink pattern layer 3 ... UV-curable paint 4, 29 ... Metal plate 5 ... Adhesive 6. ..Vinyl chloride resin metal plate 7 ... upper mold 8 ... lower mold 9 ... electric heater 10 ... cavity surface 11 ... vinyl chloride resin metal molded product 21, 26 ... Colored vinyl chloride resin sheet 25 ... Solid pattern layer 30, 30 ', 30' '... Vinyl chloride resin decorative sheet

Continuation of front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display area B29K 27:06

Claims (7)

[Claims] 1. Production of a molded product having a three-dimensional shape, a vinyl chloride resin decorative sheet on one side and a metal plate on the other side (hereinafter referred to as vinyl chloride resin metal molded product). In the method, after the ultraviolet-curable coating material is applied to the front side of the vinyl chloride resin decorative sheet and cured by irradiation with ultraviolet rays, the back side of the vinyl chloride resin decorative sheet and the metal plate are adhered (hereinafter referred to as (Vinyl chloride resin metal plate), then punched into a desired shape, and then molded into a three-dimensional shape by a pressing method with one or both of the mold and the vinyl chloride resin metal plate being heated. A method for producing a vinyl chloride resin metal molded product, comprising: 2. A method for producing a vinyl chloride resin metal molded article, which has a three-dimensional shape, a vinyl chloride resin decorative sheet on one side, and a metal plate on the other side. The back side of the sheet and the metal plate are bonded together, then punched into a desired shape, and then one or both of the mold and the vinyl chloride resin metal plate are heated and molded into a three-dimensional shape by a pressing method. A method for producing a vinyl chloride resin metal molded article, characterized in that the ultraviolet-curable coating material is then applied to the front side of the vinyl chloride resin decorative sheet and cured by irradiation with ultraviolet rays. 3. The temperature of the mold when molding into the three-dimensional shape is 30 to 110 ° C., more preferably 40 to 100 ° C.
The method for producing a vinyl chloride resin metal molded article according to claim 1 or 2, wherein the molding is performed by heating the molded article to a metal. 4. The vinyl chloride resin metal plate is molded at the three-dimensional shape at 30 to 110 ° C., more preferably at 40 ° C.
The method for producing a vinyl chloride resin metal molded article according to claim 1, wherein the molding is performed after heating to -100 ° C. 5. The vinyl chloride resin decorative sheet has a plasticizer content of 20 PHR or less, more preferably 1
The method for producing a vinyl chloride resin metal molded article according to claim 1, wherein a vinyl chloride resin having a PHR of 5 PHR or less is used. 6. The method for producing a vinyl chloride resin metal molded product according to claim 1, wherein the cavity surface of the mold is mirror-finished when the three-dimensional shape is molded. 7. A method for producing a vinyl chloride resin metal molded product according to claim 1, wherein the cavity surface of the mold has a matte finish when molding into the three-dimensional shape.