JPH1044187A - Manufacture of colored resin molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing efficiently a colored resin molded product of superior resistance to scuffing and resistance to impact in which a hard coat layer of transparency is formed and the surface color of colored resin can be demonstrated positively through the hard coat layer. SOLUTION: A laminate 29 composed of a transparent film 20, a transparent hard coat layer 25a of curing resin and a release film 28 is formed preliminarily. The laminate 29 is so disposed in a mold as to bring its release film into contact with molding tools 30 and 34. The colored resin 35 is injected into the mold on the hard coat side of the laminate 29, integrated with the hard coat layer 25a and molded into given shape. The release film is released from a molded product after the molded product is released from the molding tools. The hard coat layer 25a is cured completely before or after the release of the release film.

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 colored resin molded article such as a plastic outer panel for automobiles.

[0002]

2. Description of the Related Art As one of the conventional methods for producing a colored resin molded product, painting is performed on the surface of a molded product after molding. However, since this method requires a painting step after molding, the number of steps is increased, and this method cannot be said to be an economical method.

In order to omit such a coating process, a thermoplastic resin mixed with a coloring material, for example, ABS (acryl butadiene styrene), PP (polypropylene), PV
C (polyvinyl chloride), PC (polycarbonate), P
Using a resin such as PO (Noryl), a stampable sheet is formed from these resins, and the sheet is press-formed into a predetermined shape, or the thermoplastic resin mixed with a coloring material is melted. Thus, a method of injection molding this into a mold is adopted.

However, in a method of manufacturing a molded article using a resin mixed with a coloring material, there is a case where the inner surface of the mold is contaminated during the press molding or the injection molding or dust adheres to the inner surface of the mold. In such a case, there is a problem that these adhere to the surface of the molded product and a good surface finish cannot be obtained. The biggest disadvantage of this method is that it has no protective film (coating) due to the omission of the coating step, and its surface is easily scratched. That is, a molded article requiring impact properties could not be obtained.

Therefore, a method for producing a painted product using a transfer sheet, which has a high surface hardness, excellent surface properties such as abrasion resistance, is less likely to cause delamination and cracks, is disclosed in
No. 0-161121 has been proposed.

[0006] In the method for producing a decorative molded article using the transfer sheet, a first step of forming a release material layer by applying and drying a coating agent containing an electron beam curable composition on one surface of a base sheet. And a second step of forming a pattern layer by applying and drying a coating agent containing an electron beam-curable composition containing a colorant on the surface of the release material layer formed in the first step; A third step of forming an adhesive layer by applying and drying a coating agent containing an electron beam curable composition as a component so as to cover the entire surface of the release agent layer including the picture layer formed in the two steps. To form a transfer sheet,
Thereafter, the transfer sheet is placed in an injection molding mold so that the adhesive layer is in contact with the surface of the molded article, and is preformed. The mold is then tightened, and the molding resin is injected and molded. The article is taken out and the base sheet is peeled off, to obtain a molded article in which the picture layer and the release agent layer are integrally bonded to the surface.

[0007]

However, in the method of manufacturing a painted product using the transfer sheet disclosed in the above-mentioned publication, there is only one hard coat layer as a release agent layer on the pattern. When the hard coat layer is thickened to obtain this depth feeling, the curing step and the transfer sheet creation step take a long time, resulting in restrictions such as a decrease in production efficiency. There is a problem. In addition, in order to obtain the entire background color, it is necessary to mix a colorant into the adhesive layer, and if the colorant is mixed into the adhesive layer in this manner, it does not adversely affect the fusibility with the resin, Further, there is a problem that it is difficult to give a sense of depth as in the case of the above-mentioned pattern.

The present invention has been made in view of the above-mentioned conventional problems, and an object of the present invention is to obtain a good surface finish without contamination or dust on the inner surface of a mold during molding. Suitable for use in automotive outer panels, etc., provided with a transparent protective coating on the surface that is excellent in scratch resistance and impact resistance and that can give depth to the color of the colored resin and can be positively exposed. It is an object of the present invention to provide an efficient production method of a colored resin molded article.

[0009]

Means for Solving the Problems In order to achieve the above object, in the method for producing a colored resin molded product according to the present invention, a transparent film layer is provided directly above the colored resin layer, and a transparent film layer is provided directly above the transparent film layer. A hard coat layer which is transparent in a cured or semi-cured state, a composite layer provided with a release film immediately above the hard coat layer is placed in a mold comprising an upper mold and a lower mold having a predetermined mold surface. Forming the molded product, removing the molded product from the molding die, and removing the release film from the molded product, and completely or completely curing the hard coat layer before or after the release of the release film. Wherein the step of molding the composite layer in a mold includes the steps of: forming in advance a laminate comprising the transparent film layer, the hard coat layer, and the release film; and forming the laminate into a release film. Is the upper mold Or placing the hard coat layer in the mold so as to be in contact with one of the lower molds, and injecting a colored resin mixed with a coloring material into the mold on the transparent film layer side of the laminate. And a step of molding into a predetermined shape.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

First, the first embodiment of the present invention shown in FIGS.
In the method for manufacturing a colored resin molded product according to the embodiment, a thermoplastic resin colored in a predetermined color is extruded from a first extruder 1 into a film shape, which is immediately cooled to become a colored film 2, and a guide is formed. It is wound on a winding roller 4 through a roller 3. Above the first extruder 1, a second extruder 5 is provided, from which a transparent thermoplastic resin is extruded, which is immediately cooled and becomes a transparent film 6 on the colored film 2. Laminated.
On the transparent film 6, a hard coat liquid 7, for example, an acrylic resin or a silane resin that is cured by irradiation with ultraviolet rays is applied. A release film 9 made of polyester resin or the like drawn out through a guide roller 8 is placed on the hard coat liquid 7 applied to the transparent film 6.
Are tightly coated, and these laminates 10 are obtained. The laminate 10 has flexibility because the hard coat liquid is not cured, and is wound on the winding roller 4.

As described above, the formed laminate 10 is cut into a desired size by a cutter or the like while the hard coat liquid 7 is not cured, and the plate-like laminate 10 shown in FIG.
a.

Next, the above-mentioned plate-shaped laminate 10a is placed on a lower die 11 of a press die having a predetermined shape, and this is pressed by an upper die 12 as shown in FIG. By doing so, it is formed into a predetermined shape. Molded laminate 1
0a is taken out from between the lower mold 11 and the upper mold 12, and FIG.
As shown in (b), ultraviolet light is irradiated from above the release film 9 by the ultraviolet light irradiation device 13. Thus, the hard coat liquid 7 is completely cured, and the hard coat layer 7a is formed on the transparent film 6. Finally, the release film 9 is peeled off from the laminate 10a on which the hard coat layer 7a formed into a predetermined shape is formed, as shown in FIG. A resin molded product 10b is obtained. This molded product 10b is used with the hard coat layer 7a as the front and the colored film 2 side as the back.

FIGS. 5 to 8 show a method according to a second embodiment of the present invention.

In this embodiment, a transparent film 20 made of a polyester resin or the like formed in advance is used as the guide roller 2.
1, drawn out through pulling rollers 22a, 22b, passed over a feed roller 23, and wound around a winding roller 24. On this transparent film 20, a hard coat liquid 2 which is cured by irradiation of ultraviolet rays such as acrylic resin
5 is applied. Then, the hard coat liquid 25 applied on the transparent film 20 is passed through a semi-curing furnace 26, whereby the hard coat liquid 25 is heated to be in a semi-cured state. Next, the release film 28 drawn through the guide roller 27 is tightly coated on the hard coat layer 25a in the semi-cured state. These laminates 29 have flexibility because the hard coat layer 25a is semi-cured, and are wound on the winding roller 24. The laminated body 29 is cut into a desired size by a cutter or the like to form a sheet-shaped laminated body 29a as shown in FIG.

Next, the sheet-like laminate 29a is set in the upper mold 30. The upper mold 30 includes a frame 31 having a through hole communicating with the vacuum pump P, and a mold member 32 fitted in the frame 31. The mold member 32 is formed of a porous material. The inner surface of the mold member 32 forms a desired mold surface 33. When the sheet-like laminate 29a is installed in the upper mold 30, the release film 28
When the vacuum pump P is operated in this state, the sheet-like laminate 29a is formed along the mold surface 33 as shown in FIG.

Next, as shown in FIG.
0, the lower mold 34 is closed so that a gap is formed between the inner surface of the lower mold 34 and the laminated body 29a installed in the upper mold 30. A thermoplastic resin 35 mixed with a coloring material is injected.

After the thermoplastic resin 35 is cooled and solidified, the upper and lower molds 30 and 34 are opened and the molded product 29b is taken out. As shown in FIG.
5 is integrally fused to the transparent film 20 to obtain a molded product 29b serving as a backup material.

Next, as shown in FIG. 7D, the molded articles 29b obtained as described above are sequentially placed on a conveyor 36 and introduced into an ultraviolet furnace 37.
After passing through 7, the hard coat layer 25a in the semi-cured state of the molded article 29b is completely cured by the irradiation of ultraviolet rays, and the molded article 29b having a desired strength is obtained.

Finally, from the molded article 29b, FIG.
When the release film 28 is peeled off as shown in FIG. 8, the transparent film 20 is integrated on the backup layer of the colored thermoplastic resin 35, as shown in FIG. A colored resin molded article covered with the coat layer 25a is obtained.

In the above embodiment of the present invention, a transparent film is interposed between the colored resin layer and the hard coat layer. This is because the transparent hard coat layer and the transparent The depth of the color of the colored resin is increased through the film, and the depth can be increased by the thickness of the transparent film without increasing the thickness of the hard coat layer.

In the above embodiment of the present invention, the hardening treatment of the hard coat layer by irradiation with ultraviolet rays is performed before the release film is peeled off. However, the curing treatment can be performed after the release film is peeled off. The release film can be peeled off during the curing process.

[0023]

As described above, according to the method for producing a colored resin molded product according to the present invention, since the hard coat layer is molded in a mold when it is in an uncured or semi-cured state, it follows the shape of the mold surface. It has good properties and can prevent the occurrence of cracks.

Also, since the composite layer in which the hard coat layer is covered with the release film is molded in the mold, the dirt and dust in the mold are molded without adhering to the hard coat layer, and a good surface is obtained. You can get the finish.

Further, since the surface of the colored resin layer is covered with the hard coat layer, the surface becomes a molded product having excellent scratch resistance and impact resistance, and it is possible to obtain a molded product suitable as an automobile outer panel or the like. Can be.

Further, since the transparent hard coat layer is formed integrally with the colored resin layer via the transparent film,
A colored resin molded product that has a protective coating with excellent scratch and impact resistance that can be expressed while giving depth to the surface color of the colored resin by the thickness of the transparent film without increasing the thickness of the hard coat layer. It can be manufactured efficiently.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a step of manufacturing a laminate according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a plate-like laminate obtained by cutting the laminate obtained in FIG. 1 into predetermined dimensions.

3 (a) to 3 (c) are explanatory views showing steps of forming and post-treating the plate-like laminate shown in FIG. 2.

FIG. 4 is a sectional view showing a molded product obtained by the process of FIG.

FIG. 5 is an explanatory view showing a step of manufacturing a laminate according to a second embodiment of the present invention.

FIG. 6 is a cross-sectional view showing a sheet-like laminate obtained by cutting the laminate obtained in FIG. 5 into a predetermined size.

7 (a) to 7 (e) are explanatory views showing steps of forming and post-treating the sheet-like laminate shown in FIG.

FIG. 8 is a sectional view showing a molded product obtained by the process of FIG. 7;

[Explanation of symbols]

2,35 colored resin layer 6,20
Transparent film 7,25 Hard coat liquid 7a, 25a
Hard coat layer 9,28 Release film 10,29
Laminated body 11, 12, 30, 34 Mold 13 UV irradiation device

Claims (1)

[Claims] 1. A transparent film layer immediately above a colored resin layer,
An uncured or semi-cured transparent hard coat layer immediately above the transparent film layer, a composite layer provided with a release film immediately above the hard coat layer, and an upper mold having a predetermined mold surface. A step of molding in a mold comprising a lower mold; a step of removing the molded article from the mold; and a step of peeling the release film from the molded article; and a step before or after peeling of the release film. A step of completely curing the coat layer; and a step of molding the composite layer in a mold, a step of forming a laminate comprising the transparent film layer, the hard coat layer, and the release film in advance. Placing the laminate in the mold such that the release film thereof is in contact with either the upper mold or the lower mold of the mold; and placing the laminate in the mold on the transparent film layer side of the laminate. Spray colored resin mixed with coloring material Process and method for producing a colored resin molded article characterized by comprising the to be formed into a predetermined shape as well as integrated with the hard coat layer was.