JPH0966539A - Method and sheet for manufacturing acrylic resin insert molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce an acrylic resin insert molded product capable of forming fine uneveness having a sharp feeling at the edge parts thereof and taking out a high-grade quality feeling or three-dimensional feeling like the natural grain on the surface of the acrylic insert film of an insert molded product. SOLUTION: The substrate sheet 1 of an acrylic resin insert film and the uneven layer 12 of an uneven film are arranged in an injection mold in opposed relationship and both of the acrylic resin insert film and the uneven film are heated by the heating means 7 inserted in the gap between the acrylic resin insert film and the uneven film and, after the clamping of the mold, a molten resin is injected into the mold and solidified to bond the acrylic resin insert film of a resin molded product to remove the uneven film.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a surface material for furniture,
Techniques for manufacturing acrylic insert-molded products that produce insert-molded products by forming patterns such as wood grain patterns on materials used as building interior and exterior materials, cabinet surface materials, kitchen door interior materials, automobile interior parts, etc. Belong to the field.

[0002]

2. Description of the Related Art Conventionally, an insert molded article obtained by an insert molding method is used as a material used as an automobile interior part having a pattern such as a grain pattern formed thereon. The insert molding method is to place an insert film in which a pattern ink layer such as a wood grain pattern ink layer is printed on an acrylic film base in a mold for injection molding, heat the insert film, and after closing the mold, mold the molten resin. This is a method of adhering the ink layer side of the acrylic insert film to a resin molded product by injecting it into a mold and solidifying the resin.

The reason why the acrylic film substrate is used is that the acrylic film has a superior light resistance as compared with a PET film because the acrylic film has a molecular structure that makes it difficult for light rays harmful to ink to pass therethrough. An advantage of excellent "light resistance" is that, for example, fading or damage of the design ink layer caused by direct exposure of natural light or room light to the design ink layer can be effectively suppressed. Further, since the acrylic film deforms (elongates) even at a low temperature, the workability of the entire insert film is superior to that of the PET film and the like. The advantage of excellent "workability" is that, for example, the shape of the inner surface of the cavity of the injection mold is a complicated shape such as unevenness with many holes and grooves, Even if the insert film uses an acrylic film as the base sheet, it has a complicated shape and a deep rise on the inner surface of the cavity of the injection mold due to heating and vacuum suction. This is because it is possible to obtain an insert-molded product that is deformed into a shape and exhibits a surface shape similar to the shape of the inner surface of the cavity of the injection molding die.

[0004]

However, in the conventional method for producing an insert-molded article, since the surface of the acrylic film substrate is flat, for example, when the pattern ink layer is a wood grain print layer, The pattern alone did not give the texture and three-dimensional effect of natural wood grain. In addition, in order to give a three-dimensional effect, it is possible to form a texture on the injection-molding die to form irregularities on the surface of the acrylic film substrate of the insert-molded product. There was no sharp edge at the edge, and it was not possible to form fine unevenness on the surface of the acrylic film substrate in order to bring out a high-quality texture and a three-dimensional effect like natural wood grain.

In addition, if a die with a grain is required to be custom-made, or if a grain-free die or a grain with a different shape is required, the die must be prepared separately and the insert is used. The manufacturing cost of the molded product was high.

The present invention solves the above-mentioned drawbacks, has sharp edges on the irregularities, and has fine irregularities for obtaining a high-quality texture and a three-dimensional effect like natural wood grain. It is an object of the present invention to provide a method for producing an acrylic insert-molded article that can be formed on the surface of, and a sheet for producing an acrylic insert-molded article.

[0007]

In order to achieve the above object, the method for producing an acrylic insert-molded article according to the present invention is, as described in claim 1, a transparent resin containing an acrylic resin as a main component. A base sheet of an acrylic insert film in which a pattern ink layer and an adhesive layer are sequentially formed on a base sheet, and a concavo-convex layer of a concavo-convex film having a concavo-convex layer formed on the base sheet are faced to each other, and an injection molding metal The acrylic insert film and the concavo-convex film are heated by a heating means which is placed in the mold and is temporarily inserted between the acrylic insert film and the fixed mold, and the molten resin is injected into the mold after the mold is closed. By solidifying, the acrylic insert film was adhered to the resin molded product, and the uneven film was peeled off.

The method for producing an acrylic insert-molded article according to the present invention, as described in claim 2,
The heat deformation temperature of the base sheet of the concavo-convex film is lower than the heat deformation temperature of the base sheet of the acrylic insert film.

The method for producing an acrylic insert-molded article according to the present invention, as described in claim 3,
In any one of claims 2 to 3, the thickness of the base sheet of the acrylic insert film is larger than the unevenness of the uneven film.

Further, according to the sheet for producing an acrylic insert-molded article of the present invention, as described in claim 4, a pattern ink layer and an adhesive layer are sequentially formed on a transparent base sheet containing an acrylic resin as a main component. The acrylic insert film and the concavo-convex film having the concavo-convex layer formed on the base sheet were used.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The method for producing an acrylic insert molded article and the sheet for producing an acrylic insert molded article according to the present invention will be described in more detail below.

For convenience of explanation, the acrylic insert film and the concavo-convex film, which are the sheets for producing an acrylic insert molded product of the present invention, will be described first.

The acrylic insert film is a product in which a pattern ink layer 2 and an adhesive layer 3 are sequentially formed on a transparent substrate sheet 1 containing acrylic resin as a main component (FIG. 1).

The transparent base sheet 1 is a transparent resin sheet containing an acrylic resin as a main component. A transparent resin sheet containing an acrylic resin as a main component has a molecular structure that makes it difficult for light rays harmful to ink to pass therethrough, and therefore has excellent light resistance as compared with a PET film or the like.
An advantage of having excellent "light resistance" is that, for example, fading or damage of the design ink layer 2 caused by direct exposure of natural light or room light to the design ink layer 2 can be effectively suppressed. . In addition, since a transparent resin sheet containing an acrylic resin as a main component deforms (elongates) even at a low temperature, compared with a PET film or the like,
The workability of the insert film as a whole is excellent. The advantage of being excellent in “workability” is that, for example, the shape of the inner surface of the cavity 40 of the injection molding die 4 is a complicated shape such as unevenness with many holes or grooves formed. Even if it has a shape with deep rising recesses, an insert film using a transparent resin sheet containing an acrylic resin as a main component as a base sheet can be heated or vacuum sucked into an injection molding die. That is, it is possible to obtain an insert-molded product having a surface shape similar to that of the inner surface of the cavity 40 of the injection molding die 4 by deforming into a complicated shape of the inner surface of the cavity 40 of 4 and a deep rising shape. .

As the transparent base sheet 1 containing an acrylic resin as a main component, not only an acrylic film made of a pure acrylic resin such as polymethylmethacrylate, polyethylmethacrylate, polypropylmethacrylate, polybutylmethacrylate, etc. , A film of a component composed of a copolymer of an acrylic resin and another resin (for example, a fluororesin, a polystyrene resin, a polypropylene resin, a polyvinyl chloride resin, a polyester resin, a silicone resin), an acrylic film and another plastic film ( For example, a laminated film with a fluorine film, a polypropylene film, a polyvinyl chloride film, a polyester film, a polyethylene vinyl acetate film, a polycarbonate film, etc.) is also included. As a method of laminating the laminated film, there are various lamination methods such as direct lamination and dry lamination, and a method by a heat sealing method. When a biaxially stretched polyester film or a biaxially oriented polypropylene film and a pure acrylic film are laminated to form the base sheet 1, the elongation of the film is worse than that of the pure acrylic film. The stretched polypropylene film is preferably a relatively thinner film than a pure acrylic film.

The thickness of the base sheet 1 is 10 μm to 500 μm.
Although it is μm, it is preferably 50 μm or more in order to obtain sufficient light resistance. Also, in order to obtain sufficient workability, 30
It is preferably 0 μm or less. The thickness for simultaneously having good light resistance and good workability is 125 μm and 200 μm in the case of a polymethylmethacrylate base sheet.
and so on.

As the design of the design ink layer 2, wood grain design,
There are letters, symbols and numbers. The pattern ink layer 2 may be formed by using various pigments or dyes, or a bright pigment ink layer mixed with pearl powder or aluminum powder, or a metal vapor deposition layer. Hereinafter, as an example of the pattern ink layer 2, a wood grain pattern layer in which a wood grain layer and an opaque base layer are sequentially formed will be described.

The grain pattern layer expresses a grain pattern such as annual rings, fibers and conduits that appear at the cut end when the timber is cut. Specific wood grain patterns include streaks, curved lines, and line breaks. The wood grain layer is vinyl chloride vinyl acetate copolymer, polyamide, polyester,
Using a thermoplastic resin such as polyacryl, polyurethane, chlorinated rubber, or nitrified cotton as a binder and containing a dye or pigment of a woodgrain pattern as a coloring material, from brown, dark brown, ocher, red brown, etc. Select single or multiple colors. The wood grain layer is formed by a usual printing method such as an offset printing method, a gravure printing method, a screen printing method, a flexographic printing method, or a coating method such as a roll coating method or a spray coating method. Alternatively, the wood grain layer is formed on a part or the whole surface of the base sheet 1 by gradation so as to change the color density or the film thickness stepwise or continuously in order to make it closer to the natural wood grain pattern. May be. The thickness of the wood grain layer is adjusted within the range of 0.5 μm to 5 μm.

The opaque underlayer is a layer expressing the color of the wood other than the wood grain that appears at the cut end when the wood is cut.
The opaque underlayer is a vinyl chloride-vinyl acetate copolymer, polyamide, polyester, polyacrylic, polyurethane,
Using a thermoplastic resin such as chlorinated rubber or nitrified cotton as a binder and containing a dye / pigment of the color of the underlayer as a coloring material, brown, dark brown, ocher, cream, yellow, red brown, etc. Select single or multiple colors from the colors. If necessary, the color may be selected to be darker than the color selected as the wood grain layer, or may be selected to be a light color. The opaque underlayer is formed by a usual printing method such as an offset printing method, a gravure printing method, a screen printing method, a flexographic printing method, or a coating method such as a roll coating method or a spray coating method. The thickness of the opaque underlayer is
2 μm to 10 μm is suitable.

The adhesive layer 3 is preferably made of acrylic resin, urethane resin, polyester resin, polyamide resin, ethylene butyl alcohol resin, ethylene vinyl acetate copolymer, vinyl chloride / vinyl acetate copolymer or the like.

The concavo-convex film has a concavo-convex layer 12 formed on a base sheet 11. As the base sheet 11, an acrylic film made of pure acrylic resin such as polymethylmethacrylate, polyethylmethacrylate, polypropylmethacrylate, and polybutylmethacrylate, an unstretched polypropylene film, a polyvinyl chloride film, an unstretched polyester film. , Polycarbonate film and the like.

Particularly, the base sheet 11 of the uneven film is
It is preferable that it is equivalent to the base sheet 1 of the acrylic insert film or more easily deformed (extended) than the base sheet 1 of the acrylic insert film. That is, the heat distortion temperature of the base sheet 11 of the uneven film is equal to or lower than that of the base sheet 1 of the acrylic insert film.

The first advantage of using the one having a heat distortion temperature of the base sheet 11 of the concavo-convex film lower than that of the base sheet 1 of the acrylic insert film will be described. Whether the surface shape of the insert-molded product is similar to the shape of the inner surface of the cavity of the injection mold is determined by the uneven film, which is a film that directly adheres to the inner surface of the cavity of the injection mold. It depends on whether or not the shape of the inner surface of the mold cavity is deformed. This is because if the base sheet 11 of the concavo-convex film is hard to be deformed following the corners and concavities and convexities of the inner surface of the cavity of the injection molding die, only the acrylic insert film can be used for the inner surface of the cavity of the injection molding die. This is because even if an attempt is made to deform following a complicated shape or a shape with a deep rise, it is impossible because the uneven sheet that is difficult to deform is pressed down. Therefore, the base sheet 11 of the concavo-convex film is prepared by using a base sheet 11 of the concavo-convex film whose thermal deformation temperature is lower than that of the base sheet 1 of the acrylic insert film.
By making the acrylic insert film equivalent to the base sheet 1 of the acrylic insert film or more easily deformable (extensible) than the base sheet 1 of the acrylic insert film, the acrylic insert film is prevented from being pressed by the uneven film.

The second advantageous point when the heat distortion temperature of the base sheet 11 of the uneven film is lower than that of the base sheet 1 of the acrylic insert film will be described. Ideally, the acrylic insert film and the concavo-convex film are deformed in the same softened state and are brought into close contact with the inner surface of the cavity of the injection molding die. But,
As shown in FIG. 3, the concavo-convex film is heated by the heating means in a state where the heat rays from the heating means are blocked by the acrylic insert film. Therefore, the relationship of (heat received by the acrylic insert film)> (heat received by the uneven film) is inevitable, and even if the acrylic insert film is deformed to the ideal, the uneven film is better to the ideal. It will not be deformed. Therefore, as in the present invention, by using a material having a heat distortion temperature of the base sheet of the concavo-convex film lower than that of the base sheet 1 of the acrylic insert film, heat rays are blocked by the acrylic insert film. Also, the uneven film is deformed in the same softened state as the acrylic insert film, and the acrylic insert film and the uneven film are deformed in the ideal softened state.

A method of forming the uneven layer 12 on the base sheet 11 of the uneven film will be described. First, the cells of a metal mold roll plate formed in a predetermined pattern by a method such as etching is filled by dipping an ultraviolet curable or electron beam curable resin material, and the filled mold roll plate The base material sheet is placed on the cell, the resin material is cured by irradiating the back surface with ultraviolet rays or electron beams, and then the resin material is transferred to the base material sheet by peeling the resin material from the patterning plate. As the transferred portion becomes a convex portion, unevenness is formed on the base sheet. The use of UV curable or electron beam curable resin material
This is because a thick film having a thickness of 3 μm to 15 μm can be used to form irregularities having a pattern of a predetermined pattern such as a continuous pattern and having sharp pattern edges. Examples of the ultraviolet curable resin material include cyanoacrylate. Further, as the electron beam curable resin material, there are triazine acrylate and the like.

The method for producing an acrylic insert molded article of the present invention is a substrate of an acrylic insert film in which a pattern ink layer 2 and an adhesive layer 3 are sequentially formed on a transparent substrate sheet 1 containing the above acrylic resin as a main component. Sheet 1
And the concavo-convex layer 12 of the concavo-convex film in which the concavo-convex layer 12 is formed on the base sheet 11 as described above,
The acrylic insert film and the concavo-convex film are heated by the heating means 7 which is disposed in the injection molding die 4 and is temporarily inserted between the acrylic insert film and the fixed die, and the molten resin 5 is metalized after the die is closed. By injecting into a mold and solidifying the resin, an acrylic insert film is adhered to the resin molded product 6, and then the uneven film is peeled off (FIGS. 3 and 4).

First, the concavo-convex film and the acrylic insert film are placed in an injection molding die consisting of a movable die 41 and a fixed die 42 (FIG. 3). When disposing the concavo-convex film in the injection-molding die 4, the concavo-convex film may be fed one by one, or may be arranged by intermittently feeding necessary parts of the long concavo-convex film. Good. In the case of using a long concave-convex film, it is advisable to use a feeder having a positioning mechanism so that the concave-convex layer 12 of the concave-convex film and the injection molding die are in register. Further, when a long concavo-convex film is intermittently fed and arranged, if the concavo-convex film is fixed by the movable mold 41 and the fixed mold 42 after the position of the concavo-convex film is detected by the sensor, the same position is always obtained. The uneven film can be fixed with.

When the acrylic insert film is placed in the injection-molding die, the single sheet of the acrylic insert film may be fed and placed one by one, or the necessary portion of the long acrylic insert film may be intermittently placed. You may send in and arrange. When using a long acrylic insert film, it is advisable to use a feeder having a positioning mechanism so that the pattern ink layer 2 of the acrylic insert film and the injection molding die 4 are in register. Further, when the long acrylic insert film is intermittently fed and arranged, if the position of the acrylic insert film is detected by the sensor and then the acrylic insert film is fixed by the movable mold 41 and the fixed mold 42, It is convenient because the acrylic insert film can be fixed at the same position all the time, and the positional displacement of the pattern of the pattern ink layer 2 does not occur. The acrylic insert film and the concavo-convex film may be temporarily attached with an adhesive or the like, and then sent into the injection molding die for arrangement.

Next, the heating means 7 is inserted between the acrylic insert film and the fixed die 42, and the unevenness film and the acrylic insert film are heated by the heating means 7 to be softened so as to be easily deformed and moved. Vacuum suction is performed from the vacuum suction hole provided on the inner surface of the cavity of the mold to bring both the uneven film and the acrylic insert film into close contact with the inner surface of the cavity of the movable mold (this contact is also called "preforming of film"). .). As the heating means 7, there is a plate such as a metal heated plate or a heater such as an infrared irradiator. As another method, the acrylic insert film is not placed in the injection mold, but only the uneven film is placed in the injection mold, and then the uneven film is vacuum suctioned or heated to make the uneven film inside the cavity of the movable mold 41. May be closely attached to. When both the concavo-convex film and the acrylic insert film have been brought into close contact with the inner surface of the cavity of the movable die 41, the heating means 7 is retracted from between the acrylic insert film and the fixed die 42.

Next, the injection molding die 4 is closed (FIG. 4). The cavity 40 is filled with the molten resin 5 through the injection port 43 provided in the fixed mold. The acrylic insert film and the concavo-convex film are pressed against the inner surface of the cavity of the injection molding die 4 by the injected molten resin 5, so that the molten resin 5 is filled. At this time, the convex portion of the uneven film is embedded in at least the base sheet 1 of the acrylic insert film.

Next, the injection-filled molten resin 5 is solidified to form a resin molded product 6, and at the same time, an acrylic insert film is adhered to the surface thereof. The resin molded product 6 is cooled and solidified, the acrylic insert film is adhered to the resin molded product 6, the injection molding die 4 is opened, and the resin molded product 6 to which the acrylic insert film is adhered is taken out.

Next, the uneven film is peeled off. The part where the convex part of the uneven film is embedded becomes a dent and appears on the surface of the acrylic insert film. When the thickness of the base sheet 1 of the acrylic insert film is larger than the unevenness of the unevenness of the uneven film, the depression due to the convex portion of the uneven film remains within the range of the thickness of the base sheet 1 (FIG. 5).
The thickness of the base sheet 1 of the acrylic insert film is
If the unevenness of the uneven film is smaller than the unevenness of the uneven film, the depression of the uneven portion of the uneven film does not remain within the range of the thickness of the base sheet, and the pattern ink layer 2, the adhesive layer 3, the resin molded product 6
It becomes a recess that is recessed in (Fig. 6).

[0033]

Example A methyl methacrylate film having a thickness of 200 μm was used as a base sheet of an acrylic insert film. On the back surface of the base sheet, a pattern ink layer composed of a resin binder made of polyvinyl chloride resin and a heavy calcium carbonate pigment (% by weight: resin binder / pigment = 6)
0/40) was formed by the gravure printing method. An adhesive layer made of a vinyl chloride-vinyl acetate copolymer resin was formed on the pattern ink layer to obtain an acrylic insert film. An unstretched polypropylene film having a thickness of 40 μm was used as the base sheet of the uneven film. An uneven layer made of a cyanoacrylate resin and diisocyanate was formed in a thickness of 35 μm on the back surface of the base sheet.

Using the acrylic insert film and the concavo-convex film obtained as described above, the acrylic insert film is manufactured so that the concavo-convex surface of the concavo-convex film faces the base sheet of the acrylic insert film to manufacture a gearbox panel. And a concave-convex film are placed in an injection-molding die composed of a movable die and a fixed die.
Vacuum suction was carried out while heating at ℃, and it was brought into close contact with the inner surface of the cavity of the movable mold. After closing the mold, set the mold temperature to 40 ° C to 6 ° C.
While maintaining the temperature at 0 ° C., a molten resin composed of a brown acrylonitrile butadiene styrene copolymer resin heated at 220 ° C. to 250 ° C. was injected into the mold to solidify the resin. After that, the molding die was opened, the resin molded product was taken out, and the uneven sheet was peeled off.

[0035]

Since the present invention has the above-mentioned structure and operation, the following effects can be obtained. That is, since the method for producing an acrylic insert-molded article and the sheet for producing an acrylic insert-molded article of the present invention use a transparent sheet containing an acrylic resin as a main component as a base sheet for the insert film, it has excellent light resistance and processability. An insert molded product can be obtained. In addition, because the acrylic insert film base sheet is made uneven with the uneven film, the edges of the unevenness have a sharp feel, and fine unevenness is formed to bring out a high-grade texture and three-dimensional effect like natural wood grain, An acrylic insert molded product can be obtained.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of an acrylic insert film used in the method for producing an acrylic insert molded product of the present invention.

FIG. 2 is a cross-sectional view showing an example of a concavo-convex film used in the method for producing an acrylic insert molded product of the present invention.

FIG. 3 is a cross-sectional view showing one step of a method for manufacturing an acrylic insert-molded product of the present invention.

FIG. 4 is a cross-sectional view showing a step in the method for producing an acrylic insert-molded product of the present invention.

FIG. 5 is a cross-sectional view showing an example of an acrylic insert molded product obtained by the method for manufacturing an acrylic insert molded product of the present invention.

FIG. 6 is a cross-sectional view showing another example of an acrylic insert-molded product obtained by the method for manufacturing an acrylic insert-molded product of the present invention.

[Explanation of symbols]

 1 Base Sheet 11 Base Sheet 12 Concavo-convex Layer 2 Design Ink Layer 3 Adhesive Layer 4 Injection Mold 40 Cavity 41 Movable 42 Fixed Mold 43 Injection Port 5 Molten Resin 6 Resin Molded Product 7 Heating Means

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B29L 31:44 31:58

Claims (4)

[Claims] 1. A base sheet of an acrylic insert film in which a pattern ink layer and an adhesive layer are sequentially formed on a transparent base sheet containing an acrylic resin as a main component, and a concavo-convex film in which a concavo-convex layer is formed on the base sheet. The concavo-convex layer of the is placed in the mold for injection molding, the acrylic insert film and the concavo-convex film are heated by the heating means temporarily inserted between the acrylic insert film and the fixed mold, A method for producing an acrylic insert-molded product, comprising the steps of injecting a molten resin into a mold after closing and solidifying the resin to bond the acrylic insert film to the resin-molded product, and then peeling off the uneven film. 2. The method for producing an acrylic insert molded article according to claim 1, wherein the base sheet of the concavo-convex film has a heat distortion temperature lower than that of the base sheet of the acrylic insert film. 3. The method for producing an acrylic insert molded article according to claim 1, wherein the thickness of the base sheet of the acrylic insert film is larger than the level difference of the unevenness of the uneven film. 4. An acrylic insert film in which a pattern ink layer and an adhesive layer are sequentially formed on a transparent base sheet having an acrylic resin as a main component, and a concavo-convex film in which a concavo-convex layer is formed on the base sheet. A sheet for producing an acrylic insert molded product, which is characterized in that